2. Professors
  3. CARLONE Pierpaolo
  4. Teaching

STRUCTURAL DESIGN AND MANUFACTURING OF MECHANICAL COMPONENTS

Pierpaolo CARLONE STRUCTURAL DESIGN AND MANUFACTURING OF MECHANICAL COMPONENTS

0623000011
DEPARTMENT OF INDUSTRIAL ENGINEERING
EQF7
SMART INDUSTRY ENGINEERING
2024/2025

OBBLIGATORIO
YEAR OF COURSE 2
YEAR OF DIDACTIC SYSTEM 2021
AUTUMN SEMESTER
CFUHOURSACTIVITY
1STRUCTURAL DESIGN AND MANUFACTURING OF MECHANICAL COMPONENTS
660LESSONS
2STRUCTURAL DESIGN AND MANUFACTURING OF MECHANICAL COMPONENTS
660LESSONS
ROBERTO GUGLIELMO CITARELLA1 T Curriculum
VENANZIO GIANNELLA1 Curriculum
PIERPAOLO CARLONE2 Curriculum
VITANTONIO ESPERTO2 Curriculum
ExamDate
STRUCTURAL DESIGN AND MANUFACTURING OF12/02/2025 - 14:00
STRUCTURAL DESIGN AND MANUFACTURING OF12/02/2025 - 14:00
Objectives
THE COURSE PROVIDES THE FUNDAMENTAL CONCEPTS AND METHODOLOGICAL TOOLS FOR THE ANALYSIS AND PLANNING OF INNOVATIVE MANUFACTURING PROCESSES USED FOR THE PRODUCTION OF MECHANICAL COMPONENTS. CONVENTINAL TECHNIQUES, BASED ON SOCTRACTIVE AND CONSERVATIVE APPROACHES ARE RECALLED, PROVIDING RELEVANT DETAILS ON TOOLS, EQUIPMENTS, MACHINES AND PROGRAMMING METHODS. INNOVATIVE METHODS, BASED ON ADDITIVE AND ROBOTIC MACHINING, AND SURFACE TREATMENT AND ENGINEERING TECHNOLOGIES ARE PRESENTED.
FURTHERMORE, STARTING FROM THE BASIC NOTIONS OF CONTINUUM MECHANICS, BRIEFLY RECALLED AT THE BEGINNING OF THE COURSE, THE STUDENT WILL LEARN THE THEORETICAL AND APPLICATIVE FUNDAMENTALS OF THE FINITE ELEMENT METHOD (FEM) AT AN ADEQUATE LEVEL TO SOLVE SIMPLE STATIC LINEAR PROBLEMS. MOREOVER, THE STUDENT WILL LEARN THE BASICS OF EXPERIMENTAL MECHANICS, MECHANICAL CHARACTERIZATION OF MATERIALS AND STRUCTURAL HEALTH MONITORING.

1)KNOWLEDGE AND UNDERSTANDING.
AT THE END OF THE COURSE, THE STUDENT WILL BE ABLE TO:
- CHOOSE THE MOST APPROPRIATE MANUFACTURING PROCESSES TO CREATE SURFACES/COMPONENTS THAT MEET THE DESIGN REQUIREMENTS AND POST-PROCESS TREATMENTS, KNOW HOW TO INTEGRATE INNOVATIVE ADDITIVE PROCESSES WITH CONVENTIONAL PROCESSING SYSTEMS, SELECT THE MOST SUITABLE INSPECTION METHODS FOR THE PRODUCT CONSIDERED BASED ON MECHANICAL AND FUNCTIONAL PROPERTIES;
- DEVELOP THE PART PROGRAM OF A COMPONENT USING A CAD/CAM APPROACH;
- FORMULATE PHASE SHEET AND CYCLE SHEET FOR THE MANUFACTURING OF THE MECHANICAL COMPONENT;
- PERFORM STRUCTURAL ANALYSES BASED ON THEORETICAL ARGUMENTS DEVELOPED DURING THE COURSE, LEVERAGING ON THE CAPABILITIES OFFERED BY FEM;
- PERFORM THE MECHANICAL CHARACTERIZATION OF A MATERIAL.


2)AUTONOMY OF JUDGMENT
BEING ABLE TO IDENTIFY AND PLAN CONVENTIONAL, INNOVATIVE OR ADDITIVE PROCESSING STRATEGIES, POST-PROCESS TREATMENTS AND THE MOST APPROPRIATE INSPECTION METHODS TO CREATE OR VERIFY SURFACES THAT MEET THE SPECIFICATIONS IMPOSED BY THE DRAWING.
AUTONOMY OF JUDGEMENT IS ALSO ENCOURAGED IN THE EXAM PREPARATION PHASE. IN FACT, THE LATTER INVOLVES THE DISCUSSION OF A COMPUTATIONAL REPORT, BASED ON THE FINITE ELEMENT METHOD. IN ORDER TO PREPARE FOR IT THE STUDENTS CAN USE REGULATIONS, MANUALS, SOFTWARE.


3)COMMUNICATION SKILLS
BEING ABLE TO DESCRIBE, IN WRITTEN FORM, IN A CLEAR AND CONCISE WAY AND ORALLY PRESENT THE OBJECTIVES USING TECHNICAL-SCIENTIFIC LANGUAGE, THE PROCEDURE AND THE RESULTS OF THE PERFORMED ELABORATIONS. MOREOVER, AN IMPORTANT PART OF THE COURSE CONSISTS IN THE PRODUCTION OF A REPORT BASED ON A FINITE ELEMENT ANALYSES OF SIMPLE STATIC LINEAR PROBLEMS. THIS ACTIVITY WILL BE CARRIED OUT BY GROUPS OF TWO STUDENTS WHOSE FRUITFUL INTERACTION WILL BE OF THE UTTERMOST IMPORTANCE IN ORDER TO SOLVE THE POSED PROBLEMS.

4)LEARNING SKILLS
BEING ABLE TO APPLY THE KNOWLEDGE ACQUIRED IN CONTEXTS DIFFERENT FROM THOSE PRESENTED DURING THE COURSE, AND TO DEEPEN THE TOPICS COVERED USING MATERIALS OTHER THAN THOSE PROPOSED. APPLICATION OF THE ACQUIRED KNOWLEDGE IN CONTEXTS DIFFERENT FROM THOSE PRESENTED DURING THE COURSE.
Prerequisites
IT IS REQUIRED A KNOWLEDGE OF MATHEMATICS, PHYSICS, FUNDAMENTALS OF MACHINE DESIGN, MECHANICAL DRAWING, AND MECHANICAL ELEMENTS MODELLING, BASIC MATERIALS SCIENCE AND MANUFACTURING, AT A LEVEL CONSISTENT WITH THE BACHELOR DEGREE IN INDUSTRIAL ENGINEERING.
Contents
CONVENTIONAL MANUFACTURING PROCESSES (THEORY HOURS 8).
FUNDAMENTALS OF MACHINING, FORMING, WELDING. CRITERIA FOR PARAMETERS AND TOOLS SELECTION. MANUFACTURING ISSUES AND DESIGN FOR MANUFACTURING. MACHINES, TOOLS AND EQUIPMENTS (CNC, CMM, ROBOT)

PROGRAMMING OF MACHINES (THEORY HOURS 8, EXERCITATIVE HOURS 8, LABORATORY HOURS 6).
MANUAL AND AUTOMATED DEVELOPMENT OF PART PROGRAMS. STANDARD ISO6983. REFERENCE SYSTEMS, TOOL COMPENSATION, ABSOLUTE AND INCREMENTAL PROGRAMMING. CAD/CAM PROGRAMMING

ADDITIVE MANUFACTURING PROCESSES: LASER AND ELECTRON BEAM TECHNOLOGIES, METAL POWDER CHARACTERISTICS, DIRECT WIRE DEPOSITION, POWDER BED PROCESSING (LASER AND ELECTRON BEAM). POST PROCESSING AND HEAT TREATMENT. ADDITIVE MANUFACTURING OF COMPOSITES: DEPOSITION OF LONG AND SHORT FIBER REINFORCED COMPOSITES; 4D PRINTING; DESIGN FOR ADDITIVE AND COST ESTIMATION
SURFACE ENGINEERING PROCESSES: THERMAL AND COLD SPRAY PROCESSES OF POWDER ON METAL AND COMPOSITE COMPONENTS, MECHANICAL AND ELECTROCHEMICAL PROCESSES FOR SURFACE TREATMENT.


NON-DESTRUCTIVE TESTING (THEORY HOURS 2, EXERCITATIVE HOURS 2).
PENETRATING LIQUIDS, ULTRASONIC TESTING, X-GRAPHY, TOMOGRAPHY

PHASE SHEET AND CYCLE SHEET (THEORY HOURS 4, EXERCITATIVE HOURS 4).
CHECK AND OPTIMIZATION FOR MANUFACTURING OF MECHANICAL COMPONENTS, TRANSFER OF TOLERANCES, FORMULATION OF PRODUCTION AND INSPECTION DOCUMENTS


INTRODUCTION TO STRUCTURAL ANALYSIS (THEORY HOURS 10).
RECALLS OF FUNDAMENTALS OF CONTINUUM MECHANICS. INTRODUCTION TO BEAM STRUCTURES, SIMPLE STRESS STATES: TENSILE, BENDING, SHEAR AND TORSION. STRENGHT TESTS: DEFINITION OF LIMIT AND ADMISSIBLE STRESS, MULTIAXIAL STRESS STATE: FAILURE CRITERIA.

INTRODUCTION TO THE FINITE ELEMENT METHOD (THEORY HOURS 18, EXERCITATIVE HOURS 8).
FINITE ELEMENT DISCRETIZATION OF A STRUCTURE, STIFFNESS MATRIX, BOUNDARY CONDITIONS. THE TYPES OF FINITE ELEMENTS: ROD ELEMENTS, BEAM, STRESS AND STRAIN PLANE, 3D ELEMENTS, CHOICE OF THE TYPE ELEMENT TO BE USED ACCORDING TO THE OBJECTIVE OF THE ANALYSIS. FINITE ELEMENT MODELING TECHNIQUES: "FREE MESH" AND MAPPED MESH, THE USE OF CAD MODELS FOR FINITE ELEMENT ANALYSIS: OPPORTUNITIES AND PROBLEMS, HOW TO USE GEOMETRIC AND LOAD SYMMETRIES. CRITICAL ANALYSIS OF RESULTS: MODEL VALIDATION, CRITERIA OF ACCEPTABILITY OF RESULTS, CONVERGENCE ANALYSIS.
NUMERICAL APPLICATIONS: NUMERICAL APPLICATIONS ARE PROPOSED ON THE TOPICS COVERED DURING THE COURSE.

EXPERIMENTAL STRESS ANALYSIS (THEORY HOURS 8, EXERCITATIVE HOURS 6, LABORATORY HOURS 6).
THEORY AND EXPERIMENTAL APPLICATIONS TO ASSESS THE STRESS- STRAIN FIELDS IN A MECHANICAL COMPONENTS, EXPERIMENTAL CHARACTERIZATION OF THE NOTCH EFFECT, EXPERIMENTAL CHARACTERIZATION OF RESIDUAL STRESSES. FUNDAMENTALS OF STRAIN GAUGES. MECHANICAL TEST: TENSILE TEST, FATIGUE TEST, CRACK PROPAGATION TEST, TESTS FOR THE DETERMINATION OF THE KIC, TESTS FOR THE DETERMINATION OF THE K THRESHOLD. STANDARDS OF MECHANICAL TESTING, AS PART OF THE MECHANICAL DESIGN PROCESS. CRACK GAUGES AND STRAIN GAUGES. THE DESIGN OF THE EXPERIMENT: CALIBRATION OF THE EXPERIMENTAL METHOD AND ITS SENSITIVITY, SIGNAL PROCESSING, ANALOG AND DIGITAL ACQUISITION.


STRUCTURAL HEALTH MONITORING (THEORY HOURS 4)
ADVANTAGES AND DISADVANTAGES OF AN SHM SYSTEM COMPARED TO CND, "INTELLIGENT" MATERIALS AND STRUCTURES, TYPES OF SHM SYSTEMS (ACTIVE OR PASSIVE, APPLIED OR INTEGRATED/EMBEDDED), SENSORS AND SHM TECHNIQUES, OPTIMISATION OF MONITORING AND EXPERIMENTAL SET-UP, RELIABILITY OVER TIME, ULTRASOUND GUIDED WAVES.
Teaching Methods
THE COURSE IS STRUCTURED IN THEORETICAL LESSONS AND CLASSROOM EXERCISES INTEGRATED WITH LABORATORY VISITS AND PRACTICAL DEMONSTRATIONS OF MECHANICAL PROCESSING AND MEASURING CYCLES, AS WELL AS NUMERICAL APPLICATIONS CONRNING FEM ANALYSIS. CREATION OF WORKING GROUPS FOR THE PROJECT WORK (FEM APPLICATIONS), TO BE PRESENTED AND DISCUSSED DURING THE EXAMINATION.
THE THEORETICAL LESSONS ILLUSTRATE THE FUNDAMENTAL ASPECTS OF CONVENTIONAL, INNOVATIVE AND ADDITIVE PROCESSING OF METALS AND COMPOSITES, THE TECHNIQUES FOR THE TREATMENT AND ENGINEERING OF SURFACES, THE STRUCTURE AND COMPONENTS OF NUMERICALLY CONTROLLED TOOL MACHINES AND COORDINATED MEASURING MACHINES, PROGRAMMING METHODS, INSPECTION METHODS, NUMERICAL ANALYSIS AND EXPERIMENTAL MECHANICS.
THE EXERCISES ARE AIMED AT THE IMPLEMENTATION OF ALL THE DOCUMENTS AND PROGRAMS FOR THE MANUFACTURING OF A GENERIC MECHANICAL COMPONENTS, AS WELL THE APPLICATION OF FINITE ELEMENT METHOD TO STRUCTURAL DESIGN. THE EXECUTION OF THE EXERCISES IS PERFORMED BY THE TEACHER INVOLVING EVENTUALLY ANY OR MORE STUDENTS IN THE RESOLUTION. THE DEMONSTRATIONS IN THE LABORATORY ARE AIMED AT PROVIDING A PRACTICAL REVIEW OF THE THEORETICAL NOTIONS EXPLORED IN THE THEORETICAL LESSONS.
Verification of learning
THE EVALUATION OF THE ACHIEVEMENT OF THE OBJECTIVES WILL TAKE PLACE BY AN ORAL INTERVIEW WHERE A PROJECT DEVELOPED WITHIN THE COURSE WILL BE PRESENTED AND THE DEGREE OF KNOWLEDGE ACQUIRED AND THE ABILITY OF EXPOSURE OF THE DISCUSSED TOPICS WILL BE ASSESSED. THE TOTAL ASSESSMENT IS EXPRESSED IN THIRTYTHS WITH POSSIBLE HONOR.

THE MINIMUM ASSESSMENT LEVEL (18/30) IS ATTRIBUTED WHEREAS THE STUDENT DEMONSTRATES A BARELY SUFFICIENT UNDERSTANDING OF PRESENTED MANUFACTURING PROCESSES, CNC MACHINE AND PROGRAMMING, STRUCTURAL ANALYSIS AND MONITORING AND FEA, HAS A POOR DISPLAY CAPACITY AND LIMITED AUTONOMY AND JUDGMENT.
THE MAXIMUM LEVEL (30/30) IS ATTRIBUTED WHEREAS THE STUDENT DEMONSTRATES A COMPLETE AND IN-DEPTH KNOWLEDGE OF THE ANALYSED INSTRUMENTS AND METHODS AND IS ABLE TO SOLVE THE PROPOSED PROBLEMS BY IDENTIFYING THE MOST APPROPRIATE WORKING AND PROGRAMMING STRATEGIES AND SHOWS A REMARKABLE CAPACITY IN PROCESS PLANNING, AND AN EXCELLENT UNDERSTANDING OF THE THEORETICAL DEVELOPMENT OF THE FORMULAS RELATED TO THE STRESS ANALYSIS, EXHIBITING A GOOD KNOWLEDGE OF THE EMPLOYED FINITE ELEMENT METHOD AND EXPERIMENTAL TESTS. THE FINAL MARK EXPRESSED IN THIRTIETHS WITH POSSIBLE HONOR.
THE HONOR IS AWARDED WHEREAS THE CANDIDATE DEMONSTRATES SIGNIFICANT MASTERY OF THE THEORETICAL AND OPERATIONAL CONTENTS AND SHOWS HIS ABILITY TO PRESENT THE TOPICS WITH SIGNIFICANT LANGUAGE PROPERTIES AND AUTONOMOUS PROCESSING CAPACITY EVEN IN CONTEXTS OTHER THAN THOSE PROPOSED BY THE TEACHER.

Texts
NOTES FROM THE LECTURES
PETER SMID, CNC PROGRAMMING HANDBOOK, INDUSTRIAL PRESS INC.
MIKELL P. GROOVER, INTRODUCTION TO MANUFACTURING PROCESSES, WILEY
I. GIBSON, D. ROSEN, B. STUCKER: ADDITIVE MANUFACTURING TECHNOLOGIES, SPRINGER, 2015
FERDINAND P. BEER, MECCANICA DEI SOLIDI, MCGRAW-HILL, MILANO, 2006

Lessons Timetable

  BETA VERSION Data source ESSE3 [Ultima Sincronizzazione: 2025-01-27]