Advanced Manufacturing Processes

Synthetic program:

TECNOLOGIA MECCANICA 2
Aspetti generali relativi ai processi di lavorazione non convenzionali: principi fisici, modellazione, applicazioni. Tecnologia laser: generazione e caratteristiche del fascio laser, interazione laser-materia, processi (taglio, saldatura, trattamento termico, marcatura, riporto), sistemi laser. Tecnologia water jet: generazione e caratteristiche dei getti liquidi ad alta pressione, parametri e qualità della lavorazione, intensificatori di pressione. Altri processi di tipo termico (taglio plasma, elettroerosione, lavorazioni electron beam / ion beam) e meccanico (lavorazioni a ultrasuoni). Lavorazioni chimiche ed elettrochimiche. Tecnologia delle microlavorazioni meccaniche: processi di asportazione del materiale in ambito micro, macchine, applicazioni, modelli di formazione del truciolo.Scelta e valutazione economica dei processi di lavorazione non convenzionali.

Classification framework for both traditional and advanced manufacturing processes. Classification and overview of special processes, based on the type of energy applied (thermal, mechanical, electrochemical, etc.) and the tool as a “beam” of energy. General modelling of processes and systems. Distinctions and feature of physical, logical and mathematical (analytical, numerical, empirical) models.

THERMAL PROCESSES
Thermal modelling. Review of fundamentals of heat transfer. The heat equation and its practical applications in thermal machining and heat treatments. · Laser beam processing. Fundamentals of the physics of lasers: stimulated emission, properties of the laser beam. The technology of laser generation (sources) and transmission (optics, glass fibres). Interaction mechanisms between the laser beam and the engineering materials. Laser beam machining by fusion, melt and blow, vaporization and ablation. Laser beam (conduction and keyhole) welding. Other applications of lasers. · Additive manufacturing processes. Overview of the main processes/systems for metals (SLM, EBM, etc.). Product quality and examples of applications. · Electro discharge machining. The technology of EDM by plunge and wire. The mechanism of material removal by spark erosion. Process parameters influence and cutting quality. Applications. · Plasma arc processing. Properties of plasmas. The technology of plasma beam generation: historical evolutions of plasma torches. Process parameters influence and cutting quality. Other applications of plasmas.

MECHANICAL PROCESSES
Waterjet processing. Introduction to pure and abrasive waterjet machining. The technology of WJ/AWJ systems: pumps and pressure intensifiers, the cutting head and its components. Modelling the jet formation and the interaction mechanisms between the jet and the engineering materials. Process parameters influence in AWJ machining and cutting quality. Empirical modelling and cost optimization of waterjet machining. · Flexible forming processes. Hydroforming of tubes: systems, loading curves, forming mechanisms and main applications. Fluid and flexible forming of sheets: systems and applications. · Ultrasonic processing. The technology of vibrations generation: electromagnetic and piezoelectric transducers, the sonotrode. Interaction mechanisms between the tool, the abrasive slurry and fragile materials. Main applications of the process. The process of ultrasonic welding: process parameters and applications. · Micromachining. Main differences between traditional machining and ultra-precision machining. Typical tolerances and application of micromachining. Examples of systems.