OVERVIEW

Through an integrated approach that combines theory and practice, the Manufacturing Technology course prepares students to understand production processes, equipping them with the necessary skills to tackle the challenges of modern manufacturing and innovate in a continuously evolving technological context. The course focuses on:

• Mechanical metrology for the geometric, dimensional, and surface analysis of machined products, where students will learn measurement techniques and the use of measuring instruments;
• Theoretical models and dynamics involved in subtractive processes, with a focus on turning, milling, drilling, and grinding;
• Additive manufacturing, examining the operating principles and industrial applications of 3D printing methods for polymers and metals;
• Joining processes through welding and adhesive bonding, introducing the main techniques, principles, and applications.

AIMS AND CONTENT

LEARNING OUTCOMES

The course provides knowledge about mechanical metrology for geometric, dimensional, and surface-finishing analysis of machined products; and metal cutting, considering the basic theoretical models, the main processes and machine tools. The course also provides the fundamentals of additive manufacturing, welding, and adhesive bonding.

AIMS AND LEARNING OUTCOMES

At the end of the course, the student will be able to:

1. make measurements of length using instruments normally found in the production departments of industries;
2. understand the main parameters for evaluating the microgeometry of surfaces and the operation of dedicated instrumental apparatus;
3. employ simple theoretical models (kinematic, dynamic, thermodynamic) to evaluate forces, powers, temperatures as a function of the cutting parameters adopted;
4. deterministically evaluate tool life;
5. classify and select tool materials on the basis of their chemical-mechanical characteristics;
6. understand the operation of the main metal cutting operations and related machine tools;
7. recognize the main additive technologies and know their potential and limitations;
8. understand the criteria behind the selection of the most suitable joining method for the material and application.

PREREQUISITES

Elements of calculus and geometry, precisely derivatives, integrals, and trigonometry.

Basic concepts related to material properties, stress, strain, hardness

TEACHING METHODS

Teaching consists of lectures, during which the lecturer will also show physical pieces and films to facilitate understanding of the various aspects of the technologies/processes covered.

Lectures will also be given in the laboratory, where it will be possible to see tools, equipment and machines used in subtractive and additive manufacturing processes and joining methods.

Note: Students with certification of Specific Learning Disorders (SLD), disabilities, or other special educational needs are invited to contact the instructor at the beginning of the course to agree on teaching and examination methods that, while respecting the learning objectives, take into account individual learning styles and provide suitable compensatory tools.

SYLLABUS/CONTENT

1. Introduction to Manufacturing Technology

Technology and manufacturing; Fabrication by process and by parts; Fabrication and assembly stages; The manufacturing system; Design and development; Rapid prototyping; Product design; Concept of sustainability; Choice of materials and manufacturing processes; Integrated manufacturing systems.

2. Metrology and product quality

Recalls to tolerances; Mechanical metrology; Measurement and uncertainty; Statistical analysis for repeated readings; Tools for dimensional and geometric analysis of parts; CMM systems; Nonius and micrometer screw; Types and use of gauges; Types and use of micrometers; Surface condition and roughness; 2D and 3D surface analysis tools; Quality assurance: TQM and SQC; Control charts.

3. Metal cutting

Motions and velocity; Elementary tool; Mechanisms of chip formation; Orthogonal cutting: kinematics and dynamics; Cutting power; Thermodynamics of cutting; Tool materials; Tool wear forms; Turning; Milling; Drilling; Grinding.

4. Additive Manufacturing

Principles of Additive Manufacturing; Fused Deposition Modeling (FDM) for polymers and composites; Selective Laser Sintering (SLS); Stereolithography (SLA); PolyJet; Selective Laser Melting (SLM); Binder Jetting. Design for Additive Manufacturing; Industrial applications and sustainability.

5. Joining Technologies

Fundamentals of welding: definitions, structure and thermodynamics of a welded joint; Main technologies: Electric arc welding (SMAW, MIG/MAG, TIG, submerged arc); Resistance welding (RSW); Solid state welding (FSW). Principles of adhesive-bonding: Applications, Advantages and disadvantages, Types of failure, Process steps. Hybrid weld-bonded joints.

RECOMMENDED READING/BIBLIOGRAPHY

Course slides distributed at the beginning of class through the Aulaweb page.

Collection of exercises provided by the lecturer.

TEACHERS AND EXAM BOARD

LESSONS

LESSONS START

https://corsi.unige.it/en/corsi/11881/studenti-orario

Class schedule

The timetable for this course is available here: Portale EasyAcademy

EXAMS

EXAM DESCRIPTION

The exam consists of a written test and an oral test, both held on the same day. Only those who pass the written test are allowed to take the oral test.

The written test focuses on the theory of chip removal cutting and the related machining processes. It consists of an exercise made up of several questions, formulated on the basis of the exercises provided on Aulaweb and covered during lectures. The test is considered passed if the candidate has correctly completed more than half of the questions.

A positive result in the written exam cannot be carried over to subsequent sessions.

The oral test consists of one or more questions aimed at assessing the student’s acquired knowledge and may cover any of the topics covered during the lectures in the current academic year.

NOTES:

1. If the number of students enrolled in the exam is high, a completely written test may be given, consisting of a calculation exercise and one or more theory questions (open- and/or closed-ended). The rules for taking the exam and the related assessment criteria will be explained to students at the beginning of the lecture period, published on the course's Aulaweb page, and in any case posted on Aulaweb in the days leading up to the exam date. 

2. Students with certification of Specific Learning Disorders (SLD), disabilities, or other special educational needs are invited to contact the instructor at the beginning of the course to agree on teaching and examination methods that, while respecting the learning objectives, take into account individual learning styles and provide suitable compensatory tools.

3. Registration for the exam must be done exclusively through the relevant portal at https://servizionline.unige.it. Students who are unable to attend the scheduled exam are advised to deregister and/or notify the instructor of their absence in advance. 

ASSESSMENT METHODS

In the written exam, students must demonstrate that they have understood the topics explained during the lessons and, in particular, that they know how to solve problems based on the definitions and models studied. The topics covered in the written exam are chip removal and the main related processes. 
The oral exam consists of an assessment of what has been learned and the ability to critically apply the models and concepts taught. The student's preparation is assessed by verifying their ability to apply the concepts learned in class, demonstrating not only rote learning but above all a mature assimilation of the concepts. The correctness of the content, the completeness of the explanations/reasons provided, the clarity of the presentation, and the appropriateness of the technical terminology used are therefore evaluated.