The objective of this Course is to provide in-depth knowledge on main manufacturing processes and technologies. Specifically, the Course will cover: metal casting processes, bulk deformation processes, sheet metal forming processes, welding processes, standard and non-conventional material removal and cutting processes, finishing processes. Also, tool materials, tools, machine tools, manufacturing systems and NC programming will be treated.
| Lectures and exercises |
hours |
| Topics |
Specific contents |
|
| Cutting-Tool materials |
Classification of cutting tool materials. HSS. Cemented carbides. Cermets. Ceramics. CBN.PCD. |
3
|
| Metal casting |
Mechanics of solidification in metal alloys.
Classification of casting processes. Casting of shapes. Expendable mold casting and permanent mold casting processes.
Main defects of cast products. Design considerations in casting.
Design of the die. |
12
|
| Bulk deformation processes |
Mechanical behaviour ant testing of materials for engineering applications.
Classification of bulk deformation processes. Rolling. Forging. Drawing. Extrusion. Sheet metalworking processes.
Die design. Estimation of forces in forging. |
12
|
| Joining and parting processes |
Classification. Fusion welding. Resistance welding. Electric arc welding. Parting processes.
Main defects of welded products. Weldability of materials. Nondestructive testing. |
10
|
| Tool geometry and tool wear |
Fundamentals of metal cutting. The specific cutting pressure.
Tool geometry. Tool angles. Chip-breaking. Types of chip.
Tool wear. Tool wear mechanisms, characteristics and measurement criteria. Taylor equation. |
6
|
| Machining processes |
Turning. Milling. Shaping and planing. Broaching. Drilling. Sawing. |
16
|
| Grinding and finishing operations |
Classification of grinding processes. Grinding wheels. Mechanics of grinding. Dressing and shaping of grinding wheels.
Honing. Superfinishing. Polishing. Lapping. |
6
|
| Advanced manufacturing processes |
Chemical machining. Elctro-chemical machining. Electrical Discharge machining. Water-jet and abrasive-jet. Ultrasonic machining. Laser-beam, electron-beam, plasma machining. |
3
|
| Machine tools |
Main components of a machine tool. Linear axes. Motors.
Lathe. Milling machine. Drilling and boring machines. Broaching machine. Hobbing and gear shaping machines. Grinding machine |
6
|
| Automation and computer-aided manufacturing |
Compoenents of modern CNC machine tools.
Fundamentals of ISO programming of CNC machine tools. |
8
|
| Planning and economics of manufacturing operations |
Planning and economics of manufacturing operations.
The production cycle.
Optimization of machining operations. |
14
|
| Gear manufacturing |
Hobbing. Fellows-shaping. Gear finishing processes: shaving, grinding, honing and lapping. |
4
|
| Total hours for lectures and exercises |
100 |
| for exercises only |
20 |
|
Further educational activities
|
hours
|
| Labs |
0 |
| Tutorials / Seminars |
0 |
| Workshops |
0 |
| Guided tours |
0 |
| |
0 |
| Total hours for further educational activities |
0 |
| Total hours |
100
|