B000073 - PROCESS PLANNING AND COMPUTER AIDED MANUFACTURING

Italian

This course introduces you to manufacturing, with emphasis on the following intertwined themes:
a) Manufacturing processes (casting, forming, machining, joining);
b) Equipment and automation;
c) Variation and quality;
d) Process Planning

General readings:

- Giusti F., Santochi M., "Tecnologia Meccanica e Studi di Fabbricazione", casa ed. Ambrosiana
- Gabrielli F., Ippolito R., Micari, F., "Analisi e Tecnologia delle lavorazioni Meccaniche", ed. McGraw Hill
- Kalpakjian S., Schmid S.R., "Tecnologia Meccanica", ed. Pearson

Detailed readings:

- Smith, W.F., Hashemi, J., " Scienza e Tecnologia dei Materiali", ed. McGraw Hill
- Zompì A, Levi R., "Tecnologia Meccanica - Lavorazioni per Deformazione Plastica", ed. UTET
- Zompì A, Levi R., "Tecnologia Meccanica - Lavorazioni per Asportazione di Truciolo", ed. UTET

On completion of the course, the students should have the tools and confidence to enter a manufacturing enterprise, and be able to:
• Understand the principles and techniques of casting, forming, joining and finishing operations and be able to determine their suitability.
• Internalize the four attributes by which the performance of a manufacturing process, machine, or system can be measured: quality, cost, rate and flexibility.
• Calculate and understand appropriate single-point machining relationships taking tool material and machine constraints into consideration.
• Understand the principles and appropriateness of traditional machining processes.
• Select a suitable manufacturing process in order to achieve the specified product performance and design criterion while considering cost.
• Understand the role of control in processes and systems, especially in the presence of variation.
• Be aware of the future of advanced manufacturing, via the increased roles of software, robotics, and automation. Overall, become an expert thinker in manufacturing via combining all of the above throughout the semester.

With reference to the knowledge (CC) identified for the course, reference is made to the following descriptors:
- cc6: Knowledge and understanding of production facilities and processes. Understanding the advantages and limitations of process and plant design choices in different application contexts.
- cc10: Knowledge and understanding of applicable engineering techniques and methods (and their limitations) in non-technical fields.
- cc12: Knowledge and understanding of the most suitable production process for the realization of mechanical components, and definition of process parameters able to meet the requirements of product feasibility.

With reference to the competences acquired (CA) identified for the Course reference is made to the following descriptors:
- ca8: Applying knowledge and understanding problems related to multidisciplinary engineering, taking into account the constraints also of a non-technical nature, and working in collaboration with other engineers or other professional skills typically present in manufacturing companies.
- ca10: Applying knowledge and understanding problems related to the choice of the most suitable production process for the production of mechanical components, and to define the process parameters able to satisfy the product feasibility requirements.

The course has the objective to support the development of soft skills, in particular:
- ct3: Development of an adequate expression and technical discussion of own arguments, thanks to the development of intermediate tests that requires reasoning on the physics of the manufacturing processes presented during the course.
- ct7: To respect commitments and deadlines, thanks to the strict timing of the intermediate tests (3 in the semester)

In order to successfully follow the course students have to be able to interpret and specify dimensional and geometric tolerances, be aware of materials strengths, stress and strain state. A low intermediate level of English is required.

Manufacturing Engineering and Technology is a 9-CFU course.
The learning methods presume a combination of study, discussion, and practice, designed to build fundamental knowledge and hands-on experience on the methods and challenges of manufacturing. Support material consists of a set of slides used by the teacher during the lessons.
http://e-l.unifi.it will have lecture slides, exercises handouts, archive of announcements, etc. To register to the course it is necessary to have a registration key provided by the teacher at the beginning of the course.

In order to take the exam, please register to:
http://sol.unifi.it/prenot/prenot

The level of knowledge acquired will be evaluated by three intermediate tests during the course.
Topics of the first test will be: geometric and dimensional tolerances, roughness, stress and strain states, Mohr circles. The second test will be focused on casting and forging processes, while in the third test issues related to machining will be considered.
Students that will not met performance required, will have to undergo a comprehensive written evaluation test (1.5 hour) and an oral examination. Students that will not fully met the performance expectation, will have to give just an oral examination.

Tests and oral examination aim at highlighting the acquired knowledge cc6, cc10 e cc12, and verifying the capabilities ca8 e ca10.

1. Introduction. Processing overview. Materials-process matrix. Manufacturing systems

2. Manufacturing Processes
2.1. Technological and Economic Aspects
2.2. Manufacturing capabilities: Facilities Layouts
2.3. New Product Development

3. Metrology
3.1. Dimensional and geometric tolerance
3.2. Roughness

4. Microstructure and Material properties
4.1. Introduction to Strengths of Materials/Statics Review
4.2. Physical, Mechanical and Technological properties
4.3. Principle Stresses and Mohr's Circle
4.4. Materials Selection (Ashby approach using materials selection maps)
4.5. Experimental tests: Tensile test, Hardness tests

5. Casting
5.1. Liquid to solid transition; phase diagrams.
5.2. Microstructure of castings, Solidification Time, Shrinkage
5.3. The importance of oxide films and residual stresses
5.4. Sand casting, Die-casting, Centrifugal casting, Slush casting
5.5. Shell Molding, Investment casting
5.6. High pressure Die Casting
5.7. Design for castings
5.8. Defects in castings, Porosity
5.9. Trends in casting

6. Thermo-mechanical processing (forging, extrusion and rolling)
6.1. The importance of grain size;
6.2. Forging: General deformation characteristics, Hot working, Cold working, Open die forging, Closed die forging, Impression die forging.
6.3. Rolling: dynamics, forces, design.
6.4. Extrusion: Direct and indirect extrusion processes. The role of friction in extrusion.
6.5. Sheet Metalworking: Bending, Deep Drawing, Shearing and Blanking, Ironing, Spinning
6.6. Forming Limit curve

7. Machining processes
7.1. Orthogonal cutting: Tool geometry, Chip formation, Chip types, Cutting forces, Shear angle vs. shear stress
7.2. Cutting Processes: Turning, Milling, Drilling, Boring, Broaching, Sawing
7.3. Tool materials, tool wear mechanisms, tool life (Taylor law)

8. Process planning
8.1 Theory of process planning
8.2 Steps for a successful process planning
8.3 Definition of alternative solutions
8.4 Analysis of the production cost
8.5 Selection of production parameters

The 2030 objectives that this course will support are: (9) enterprises, innovation and infrastructure and (12) sustainable production and product use