B2391 - ADVANCED AND SUSTAINABLE MANUFACTURING

Learning outcomes

The student will acquire the skill to selectadvanced manufacturing technologies for metallic material processing, as well as implementing and comprehending the relationships between process parameters and product characteristics. The student will be able to evaluate the suitability and consistency of technologies in order to obtain specific requirements for the finished product, as well as to evaluate the different processes in terms of sustainability and environmental impact.

Course contents

1. SUSTAINABILITY OF THE MANUFACTURING PROCESSES

2. ADVANCED MATERIAL REMOVAL TECHNOLOGIES

Electrical Discharge Machining (EDM) and Wire Electrical Discharge Machining(WEDM). Machines architecture and components. Process parameters. Electrodes: materials and technologies. Examples.

Chemical and electro-chemical machining processes (ECM).

Ultrasonic machining (USM). machining/welding

3. ADVANCED CUTTING TECHNOLOGIES

Mechanical cutting: Shearing technologies: blanking, piercing and punching, cutoff, fine blanking.

Thermal cutting: high energy beam cutting, Oxygen Torch cutting, Plasma cutting, Laser cutting.

Others: water jet and abrasive water jet.

4. ADVANCED WELDING TECHNOLOGIES

High power source welding: Laser welding (LW), Electron beam welding (EBW). Friction welding Technologies: Friction welding, Friction stir welding (FSW) , Solid State Bonding. Diffusion Bonding. Welding of polymers, Ultrasonic Welding.

5. PROCESSING OF METAL POWDERS

Production of powders, Powder Mixing and Blending, Compacting, Sintering. Secondary and finishing operations. Proprieties of metal powders. Components. Hot isostatic pressing. Powder forming. Metal Injection Molding (MIM) or Powder Injection Molding (PIM). Properties of P/M Products.

6. RAPID PROTOTYPING TECHNOLOGIES

Selective laser sintering (SLS) of polymers, metals and powders. Fused deposition modeling (FDM). Laminated object manufacturing (LOM).

7. ELEMENTS OF SHEET METAL FORMING

Anisotropy of metal materials and effect on production processes. Measurement of anisotropy and trend with respect to the rolling direction. Deformation states of thin components subjected to forming. Formability of sheet metal. Forming limit diagrams.

Sheet metal forming processes: Drawing, Stretching, Ironing, Hydroforming, Spinning. Incremental forming, bending.

Process problems connected with the development of friction forces, the homogeneity of distribution of the deformation on the product, work hardening, the achievement of limits of formability and resistance of the material during the process.

8. PRESSES AND FORMING MACHINES

Description of the operating principles of deformation machines: gravity hammers, double-acting hammers, screw presses, mechanical presses (crank, eccentric, toggle), hydraulic presses.

Nominal energy, process energy and available energy; shot efficiency. Process force and available force, elastic deformation energy, machine stiffness constants, mold matching precision, guide clearances, machining precision.

Recovery of elastic deformation energy, time-dependent characteristics: working stroke, process speed, nominal and effective speed, tool-material contact time, effect of contact times on hot machining.

Readings/Bibliography

1. DeGarmo , J. T. Black, Ronald A. Kohser DeGarmo's Materials and Processes in Manufacturing, 11th Edition, Wiley, ISBN

2. Michele Monno, Barbara Previtali, Matteo Strano “Tecnologia meccanica. Le lavorazioni non convenzionali” CittàStudi Edizioni, ISBN: 8825173776

3. E. Capello, Le lavorazioni industriali mediante laser di potenza, 2009, Maggioli Editore, ISBN-10: 8838741816

Teaching methods

Lectures based on powerpoint slides with in-depth analysis at the blackboard; exercises and analysis of industrial cases. Visits to Manufacturing Plants. Team working project on a selected technology.

Assessment methods

The exam aims to verify the achievement of the Learning outcomes:

· knowledge of the meaning of sustainability of manufacturing technologies and measurement metrics;

· knowledge of advanced processing technologies;

· ability to analyze and propose complex technological cycles, in relation to the adequacy and compatibility of the technologies identified to obtain specific requirements on the finished product;

· ability to find specialized bibliography on innovative technologies;

· team working skills in carrying out the study.

Preliminary or after the final test, the students must discuss the team-working project on the selected technology, a score up to 30/30 is given.

Final test is realized in a written form, it consists in open questions on all the course topics. During the test, the use of any supporting material (such as textbooks, notes, computer supports, etc) is not allowed. Test is compsed by 4 questions to be discussed in open form, a score 0-8 is given to each answer thus realizing a final score on 32 basis. An optional oral session (based on student's request) can also be added, oral session can deal on all course topics and team-working study in order to clarify student's preparation and own contribute to the team working study.

The final score is an average of team working project score, written test and optional oral discussion. For written test scores below 24/32 a weighted average will be used with an higher weight provided to written test.

At least, 5 evaluation session will be realized through the accademic year.

Tests list and results are managed through Almaesami website: [https://uniwex.unibo.it/]https:// .unibo.it/ [https://almaesami.unibo.it/]
It's mandatory to sign in on the website in order to attend the exam, the lists are closed 2 days before the exam.

Teaching tools

Updated slides can be downloaded from Insegnamenti on Line (IOL).

Login with the @studio.unibo.it account.

Office hours

See the website of Lorenzo Donati

See the website of Luca Tomesani