The Integrated Manufacturing Systems Course provides students in the fifth year of the master's degree with the basic elements for the use of numerical control in material subtraction processing. The course includes a first part dedicated to the deepening of machining by chip removal, with particular reference to the aspects of cutting mechanics as well as the tool sizing criteria for the most common turning, milling and drilling operations. In this context, the aspects concerning the problems of tool wear and Taylor's law will not be neglected. The Course also provides a second part dedicated to the optimization models of numerical control processes according to the criteria of maximum economy and maximum productivity. In addition, the strategies for the closed and numerical resolution of the main optimization models of numerical control work will be proposed. Finally, the first elements will be provided for the use of SW CAD / CAM in mechanical design, with specific reference to machining with numerical control machines.
teacher profile teaching materials
SANTOCHI, Marco; GIUSTI, Francesco. Tecnologia meccanica e studi di fabbricazione. Casa Editrice Ambrosiana, 2000.
Programme
The course focuses on the study of production technologies for chip removal and CAD/CAE/CAM (Computer-Aided Design/Computer-Aided Engineering/Computer-Aided Manufacturing) for product design and planning and programming of the product production and processing process. The mechanics of cutting and sizing of the tool will be examined. The mechanics of cutting. Recalls on the processing by material subtraction: turning, milling, drilling. Tool sizing in turning, milling and drilling. Tool interaction - material in machining by chip removal. Tool wear and Taylor’s law. Numerically controlled machining optimization. Optimization of machining parameters. Maximum economy criterion. Maximum productivity criterion. Optimal choice. Sensitivity analysis. Single-axis machining. Single-axis machining with variable feed. Multi-axis machining. Multi-axis and multi-stage machining. Advanced methods of numerical control optimization. Numerical control of machine tools. The generality of numerical control machining systems. The architecture of a numerical control machining system. Description of the components of CNC machining systems. Handling systems. References. Absolute and incremental movements. Control systems. Tools. Control unit. Design of mechanical components and preparation of the worksheet. The methodologies and techniques of three-dimensional CAD modeling of the product and the analysis and graphic representation of the functional and aesthetic requirements will be analyzed, the data structures that define the product and the production process and the issues related to the choice and application of advanced integrated IT tools to support product design activities and planning and programming of the process of production and automatic machining by CNC machine tools. The integrated CAD modeling and CAE techniques and tools for simulation and verification of the functional behavior of the product and the CAM tools for planning and programming the machining concerning the design issues will be analyzed collaborative and integration of processes and systems, systematically using application case studies of interest to the engineering industry and CAD/CAE/CAM systems available on the market. There will be guided exercises on the use of a commercial CAD/CAE/CAM system for example and the execution, using this system, of a year’s work related to the CAD design of a mechanical component and the automatic CAM programming of its machining with CNC machine tool; the execution and delivery of the work of the year is a prerequisite for taking the exam.Core Documentation
KALPAKJIAN, Serope; SCHMID, Steven R. Manufacturing Engineering. Technology, Addison-Wesley, Reading, MA (1989), 2009.SANTOCHI, Marco; GIUSTI, Francesco. Tecnologia meccanica e studi di fabbricazione. Casa Editrice Ambrosiana, 2000.
Reference Bibliography
LEE, Kunwoo. Principles of cad/cam/cae systems. 1999. THYER, G. E. Computer numerical control of machine tools. Elsevier, 2014.Type of delivery of the course
Lectures to the slide projector and blackboard. Tutorials with softwareAttendance
Classroom lessons according to the official timetableType of evaluation
The exam consists in carrying out an oral test to ascertain the skill to analyze and re-elaborate the concepts acquired and the project activities carried out during the course. The expected learning outcomes of the knowledge and communication skills are assessed by the oral exam, while the abilities to apply them, the ability to draw conclusions and the capacity for self-learning are assessed through the project.