Ing Ind - Inf (Mag.)(ord. 270) - BV (483) MECHANICAL ENGINEERING - INGEGNERIA MECCANICA
095840 - ADVANCED MANUFACTURING PROCESSES
The objective of the ADVANCED MANUFACTURING PROCESSES (AMP) class is to lead the students to completely master the main advanced processing technologies, with special reference to new processes with growing industrial importance and applied in different sectors, including automotive, aerospace, biomedical and energy. Additive, joining, shaping and subtractive manufacturing processes will be addressed, with a focus on the most innovative issues and at the key enabling technology of the “Industry 4.0” innovation. The course starts from the classification of advanced machining processes, based on the elementary mechanisms and for each process presents the basic principles, the most relevant industrial solutions, the machines and the main applications. Numerical and PC-based exercises, visits to laboratories, companies and trade fairs integrate the program.
Risultati di apprendimento attesi
After successfully taking credits for the AMP class, the students will achieve the following results.
1For each manufacturing process, they will know the basics, the main capabilities, processable materials, the achievable geometries and tolerances, the productivity performances, the typical systems and machines.
2They will master physical and empirical models that will allow them to understand the sensitivity of the processes to the main process variables. Through numerical exercises, the students will learn how to quantitatively implement the models.
3They will be able to select the appropriate technological processes for a given product, considering technical, economic and environmental issues.
4Through reading and practicing with scientific articles, they will familiarize with the scientific research approaches, they will have a clear understanding of the state of the art and they will learn how to communicate the results of research activities.
Classification framework for both traditional and advanced manufacturing processes. Classification and overview of special processes, based on the type of energy applied (thermal, mechanical, electrochemical, etc.) and the tool as a “beam” of energy.
General modelling of processes and systems. Distinctions and feature of physical, logical and mathematical (analytical, numerical, empirical) models.
·Thermal modelling. Review of fundamentals of heat transfer. The heat equation and its practical applications in thermal machining and heat treatments.
·Laser beam processing. Fundamentals of the physics of lasers: stimulated emission, properties of the laser beam. The technology of laser generation (sources) and transmission (optics, glass fibres). Interaction mechanisms between the laser beam and the engineering materials. Laser beam machining by fusion, melt and blow, vaporization and ablation. Laser beam (conduction and keyhole) welding. Other applications of lasers.
·Additive manufacturing processes. Overview of the main processes/systems for metals (SLM, EBM, etc.). Product quality and examples of applications.
·Electro discharge machining. The technology of EDM by plunge and wire. The mechanism of material removal by spark erosion. Process parameters influence and cutting quality. Applications.
·Plasma arc processing. Properties of plasmas. The technology of plasma beam generation: historical evolutions of plasma torches. Process parameters influence and cutting quality. Other applications of plasmas.
·Waterjet processing. Introduction to pure and abrasive waterjet machining. The technology of WJ/AWJ systems: pumps and pressure intensifiers, the cutting head and its components. Modelling the jet formation and the interaction mechanisms between the jet and the engineering materials. Process parameters influence in AWJ machining and cutting quality. Empirical modelling and cost optimization of waterjet machining.
·Flexible forming processes. Hydroforming of tubes: systems, loading curves, forming mechanisms and main applications. Fluid and flexible forming of sheets: systems and applications.
·Ultrasonic processing. The technology of vibrations generation: electromagnetic and piezoelectric transducers, the sonotrode. Interaction mechanisms between the tool, the abrasive slurry and fragile materials. Main applications of the process. The process of ultrasonic welding: process parameters and applications.
·Micromachining. Main differences between traditional machining and ultra-precision machining. Typical tolerances and application of micromachining. Examples of systems.
Basic knowledge of heat transfer, fluid dynamics, solid mechanics. Basic knowledge of traditional manufacturing processes (casting, metal forming, machining).
Modalità di valutazione
The final exam will consist in a written test, where the student will have to read and understand a scientific research paper and then answer some questions about the paper, which require numerical calculations. This test allows to verify knowledge and understanding, application of knowlege and understanding, learning skills.
After the test, an oral discussion will allow to assign the final grades, also checking communication abilities.
Optionally, the students can develop a project during the semester which can yield up to 2/30 additional points.
Lecture notesBeep course websiteSteen, Laser Material Processing , Editore: springer, Anno edizione: 2003
Elman, C. Jameson, Electrical Discharge MachiningCarl Sommer, Non-Traditional Machining Handbook, Editore: Advance Publishing(TX).
Gibson, Ian, Rosen, David W., Additive Manufacturing Technologies , Editore: Springer
Michele Monno, Barbara Previtali, Matteo Strano, Tecnologia meccanica. Le lavorazioni non convenzionali , Editore: CittàStudi, ISBN: 978-8825173772
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Tipo Forma Didattica
Ore di attività svolte in aula
Ore di studio autonome
Laboratorio Di Progetto
Informazioni in lingua inglese a supporto dell'internazionalizzazione
Insegnamento erogato in lingua
Disponibilità di materiale didattico/slides in lingua inglese
Disponibilità di libri di testo/bibliografia in lingua inglese
Possibilità di sostenere l'esame in lingua inglese
Disponibilità di supporto didattico in lingua inglese