Materials and manufacturing studies

Learning objectives

This course aims to provide the knowledge and skills necessary for the study of technological processes and manufacturing systems for components and industrial products. The primary objective of the course is to develop skills that allow the student to understand the production process of a mechanical component within an industrial context starting from the information present in the mechanical drawing of the part.

For this purpose, it is essential to acquire knowledge relating to the following points:
– information contained in the technical drawing in terms of part geometry, materials, surface qualities and shape and position tolerances;
– problems relating to obtaining a certain precision during processing and knowledge of the metrological instruments necessary for qualification;
– reversible and irreversible joining techniques;
– processing for chip removal on machine tools.

The ultimate objective of the course is to allow students to develop the ability to understand and manage a manufacturing cycle of a mechanical component that is technologically correct (rational and economical) and that goes through all the phases necessary for its creation.

For this purpose it is necessary to develop the following skills:
– determination of the starting raw material (in terms of dimensions, material and primary production process) for the processing of a component;
– identification of the flow of operations necessary for the creation of the component;
– reference of the component with respect to machines with appropriate equipment;
– calculation of the forces exerted during the cutting process and the powers absorbed by the machine tools.

Course content

The course aims to study technological processes and manufacturing systems of industrial parts and products, according to a systematic and coherent approach to the modeling of such processes, in order to interpret the laws and mechanisms on which they are based, to analyze their possibilities and their limits in relation to the needs of functionality and production of specific components, to the systematic design and planning of the transformation process, to the integration between product and process design through the use of the computer. A methodology will be adopted that includes theoretical lessons and exercises, during which the study and discussion of industrial cases will be addressed collectively and in a guided manner.

Bibliography

– Marco Santochi, Francesco Giusti, Mechanical technology and manufacturing studies, (2000) second edition, Casa Editrice Ambrosiana.
– Serope Kalpakjian, Steven R. Schmid, Mechanical Technology, (2008) fifth edition, Pearson Ed.

Teaching methods and tools

The course is assigned 6 credits for a total of 48 hours divided into 34 hours of lessons and 14 hours of practice. The lesson hours are distributed as follows on the main topics of the course:
– Reviews of technical drawings, tolerances and materials: 6 hours
– Machine tools: 10 hours
– Numerically controlled machine tools: 4 hours
– Welding: 4 hours
– The processing cycle: 4 hours
– Elements of industrial robotics and coordinate measuring machines: 4 hours
– Flexible production systems: 2 hours

The lessons follow the chronology necessary to complete a sequence of operations exactly as in a work cycle. This practical approach has the function of providing a guideline during the preparation of the tests in order to focus the students' efforts in creating the skills necessary to achieve the educational objectives.

The hours of practice, which require attendance of lessons or independent study of reference texts, are complementary to them and dedicated to providing, through live viewing and direct use, a practical experience aimed at developing the skills verified during the exam.

Assessment methods and criteria

The final exam verifies the acquisition of knowledge and skills by carrying out a written test lasting a maximum of 2 hours.

The written test includes 3 questions: 2 questions on knowledge and 1 skill application exercise. In particular, candidates will have to answer:
– a theoretical question in which the explanation of a machine or a production process may be requested through diagrams, definitions, demonstrations, etc.;
– a numerical exercise in which we want to verify the candidate's ability to provide quantitative results to the questions posed;
– a technical/practical exercise which consists in drawing up the processing cycle of a simple mechanical component for which a dimensioned drawing will be provided. The objective is to verify the candidates' skills in choosing the most economical and effective production cycle.

All students who have not passed the written exam can view their work by making an appointment with the teacher.