Portale di Ateneo - En.Unibs.it

Introduction on Manufacturing Processes
- the relevance of the manufacturing cycle
- problems related with the part productions (materials, shape, tolerances and costs)
- relationship between manufacturing system and final part behaviors

Casting process
- Description of the process
- Phenomena and related problems characterizing the process:
o liquid contraction: shrinkage cavities and porosities;
o solid contraction: residual stresses
- Thecnologies:
o sand casting
o shell molding process
o Pressure die casting: hot and cold chamber
o investment casting
- Sand casting:
o mold cavity design
o the holes
o Filling methods and techniques
o Estimation of the metallostatic pressure
o Examples and exercises

Bulk deformation processes
- the material plasticity
o stress and strain
o compression test for material characterization
- Hot forging:
o the machines: screw press, crank press, hydraulic press
o Die design
- Roll forging
o Flat and shape rolling
o Mannesman process
o Tube rolling
- Extrusion: direct; indirect; impact
- Wire and tube Drawing

Sheet-Metal Forming processes
- Roll forming
- Stretch forming
- Drawing
- Shearing: punching and blanking

The cutting processes
- Introduction
- theory of chip formation
- Tool materials
- Tool wear
- Turning:
o The process
o Tool angles
o tool shapes and applications
o Cutting force models
o Tool life tests and theories
o Taylor law
o Kronenberg law
o cutting process optimization.
- Milling
o Turning:
o The process
o Tool angles
o tool shapes and applications
o Cutting force models
- Drilling
o Turning:
o The process
o Tool angles
o tool shapes and applications
o Cutting force models

Non-conventional machining
- Electro discharge machining (EDM)
- Electro Chemical Machining (ECM)
- Water Jet Machining (WJM) and Abrasive Water Jet Machining (AWJM)
- LASER

Microcutting processes