B009308 - MANUFACTURING STUDIES

Italian

General objective:
to provide to the students the competencies to realize a process plan and use proficiently a CAM system

With reference to the knowledge (CC) identified for the course, reference is made to the following descriptors:
- cc3: systematic knowledge and understanding of the key aspects of mechanical design of industrial engineering and its methods. In particular: understanding of which are the most suitable methods in order to define a product and its characteristics; knowledge of the technology of the materials that can be used, of the mechanical study of parts and assemblies, their dimensioning, their static and dynamic behaviour and interactions between components. The technologies for their production and their graphic representation are also areas of knowledge and understanding.
- cc6: knowledge and understanding of production facilities and processes. Understanding the advantages and limitations of process and plant design choices in different application contexts.
- cc7: knowledge and understanding of current issues regarding the organization and management of production factors and of the principles of company management and quantitative methodologies for the analysis of profitability of an economic activity, models for defining its organizational project, for strategic analysis and determination of the business plan.
- cc8: knowledge and understanding of the wider multidisciplinary context of engineering with a particular focus on problem solving, which starts from the problem to identify causes and possible measures (typically multidisciplinary) to tackle them.
- 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:
- ca3: applying knowledge and understanding related to the most appropriate methods of analysis, modelling, verification and experimentation to design, analyze and test machines and plants. This includes: the interpretation and drafting of mechanical parts and machines (also using dedicated CAD systems); the sizing and the functional and structural verification of components and mechanical groups subjected to static and fatigue stress; the functional setting of the design of a mechanical system, applying the principles of kinematics and static principles; analysis of the characteristics of metallic and polymeric materials for the production; the choice of the best production process aimed at the creation of mechanical components; analysis and design of production systems including the study of reliability, safety and economic and environmental sustainability
- ca7: applying knowledge and understanding problems related to the choice and subsequent use of appropriate tools and methods - such as software tools for three-dimensional modeling, simulation (structural and fluid dynamics) and management of technical information – for the design and production of components and machines.

Introduction to Process Planning
Choice of the process parameters
Clamping
Introduction to CNC
Manual programming
Automatic programming
Milling basics
High Speed Milling
5 axis milling
Milling of die and models
Milling of aeronautical and automotive parts
Milling of turbine,impellers, turbochargers

Mechanical Technology
Mechanical Design

50 hours of In-class lesson
4 hours of practical exercise with CAM
Visit to manufacturing companies to view the productive processes

The level of knowledge acquired by the student will be evaluated by an oral examination provided by both teachers on process planning and manufacturing process, including the technical and technological tools for its implementation.

The student must prove the competences acquired on manufacturing process selection and process parameters definition to obtain a sufficient grade. Complementary competences are related to multidisciplinary approach to design and manufacturing process.

With reference to the knowledge (cc) and competences acquired (ca) identified for the course, oral examination aims at highlighting the acquired knowledge cc3, cc6, cc7, cc8 and cc12, and verifying the competences ca3, ca7 and ca10.

Introduction to process plan:
- semi automatic development of a process plan
- optimization of process plan

Choice of the optimal process parameters:
- selection of the optimal setup
- optimization considering costs and time

Clamping:
- theory of clamping
- examples of clamping

Introduction to CNC:
- closed loops, CNC
- reference system
- horizontal and vertical machines
- CNC milling machines

Manual programming:
- ISO language
- zero reference point
- trajectory
- compensation of the tool

Automatic programming:
- role of CAM
- input to CAM
-mathematical model: IGES format
- Curves and surfaces: NURBS, Bezier, B-splines, Coons
- Poliedric model
- CAM auxiliary functions
- tools definition
- processors and postprocessors
- realistic simulation

Milling working cycle:
- roughing
- tools for roughing
- roughing strategies
- concordance and discordance cycles
- trocoidal feed
- semi roughing
- bitangent processes
- constant step processes
- finishing

High Speed Milling (HSM):
- interaction of tool-machine tool-CNC-CAM
- role of tool in HSM
- role of Machine tool in HSM
- role of CNC in HSM
- role of Cam in HSM

5 axis milling:
- 5 axis machine structures
- mill turn machine with 4 or 5 axis
- CAM for 4 or 5 axis
- RTCP function with NC
- post processor differences with 3 and 5 axis
- alternative solution for the calculus of machine axis
- Euler angles to define the working zone

Milling of die and models:
- example of programming with CAM

Milling of aeronautical/automotive parts:
- example of CAM
- milling of inlet hoses

Milling of turbine/impeller/turgochargers:
- example of multiblade turbine
- note for the milling of thin walls

Gerald Farin, Curves and surfaces for CAGD, Academic Press
Piegl-Tiller, The NURBS book, Springer editions
Karlo Apro, Secrets of 5-Axis machining, Industrial Press

The dates of the examinations are available using the CSIAF booking system