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 master the most relevant advanced processing technologies, with special reference to 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 technologies. New “Industry 4.0” digitalization tools will be explained through relevant examples.
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, semester projects, 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.
For 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.
They will master physical, numerical (simulation) 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.
They will be able to select the appropriate technological processes for a given product, considering technical, economic and environmental issues.
Through reading and writing the semester project, they will familiarize with the scientific research, they will have a clear understanding of the state of the art and they will learn how to communicate the results of research activities.
Presentation of special processes, based on the type of application (removal, joining, welding, additive, forming) and on the field of application (automotive, aerospace, medical, etc.)
Presentation of semester project.
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 and transmission. 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. Empirical and numerical modeling, cost optimization.
Additive manufacturing processes. Overview of the main processes/systems for metals (SLM, EBM, etc.). Technological and economical comparison to conventional manufacturing. Complementary role of AM as a rapid tooling technique.
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 and tubes: systems and applications. Numerical modeling of flexible forming.
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.
Advanced machining. Evolution of traditional machining in terms of advanced work (e.g. aerospace applications) and tool (e.g. diamond coated or ceramic tools) materials, cutting fluids (e.g. cryogenic machining), simulation and control (digital twin), accuracy (e.g. ultra-precision machining).
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 solve some numerical problems and to answer some theoretical questions
This test allows to verify knowledge and understanding, application of knowlege and understanding, learning skills.
Before the first call of the winter exam session, the students, organised in groups of 4 or 5, must prepare a semester project, assigned by the teacher at the beginning of the course. The semester project is part of the evaluation, which can yield up to 2/30 additional points.
After the written test, an oral discussion will follow, allowing to assign the final grades, also checking communication abilities.
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
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