The objective of ADVANCED MANUFACTURING PROCESSES is to lead the students to completely "dominate" the main unconventional materials processing technologies, with special reference to material removal, but including also metal forming, welding, surface treatments and additive processing. The course starts from the classification of unconventional machining processes based on the elementary mechanisms and for each process presents the basic principles, the most relevant industrial solutions, and the main applications. Numerical and PC-based exercises, visits to laboratories, companies and trade fairs integrate the program.

The principal achievements are the knowledge of unconventional and innovative methods of manufacturing, and the capability of designing the entire production route of an industrial component through the correct selection of different manufaturing processes.

LIST OF CONTENTS

• Classification of unconventional manufacturing processes. A framework for traditional and unconventional 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.

THERMAL PROCESSES

• 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 fibers). 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.
• 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.
• Electron beam Machining. Properties of Electron Beam. Effect of electron beam in the thermal processing.
• Additive manufacturing processes. Overview of the main processes/systems. Product quality and examples of applications.

MECHANICAL PROCESSES

• 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. Modeling the jet formation and the interaction mechanisms between the jet and the engineering materials. Process parameters influence in AWJ machining and cutting quality. Empirical modeling and cost optimization of waterjet machining.

THERMAL MODELING

• Thermal modeling. Review of fundamentals of heat transfer. The heat equation and its practical applications in thermal processes using analytical approach.Experimental and numerical results of advanced processes will be discussed.

Requirements of knowledge related to conventional technologies of maufacturing as well as basic knowledge regarding metallic materials properties and characterizations.

The final exam will consist in a written 1-2 hours test, where the student will have to solve 2 numerical exercises and in a oral discussion of the main concepts regarding the topics of the course.

The final grade will depend on the performance during both written and oral examination.

Optionally, the students can develop a project during the semester which can yield up to 2/30 additional points.