Academic Year 2023/2024 - Teacher: Sergio FICHERA

Expected Learning Outcomes

The course deals with the description of the most used technological processes in the industrial field for the processing of metal materials and the basic elements for the management of production systems.

The expected results are:

• knowledge of the main manufacturing processes for foundries, for chip removal and for joining metal parts

• the ability to analytically solve technological problems in order to allow students to carry out an adequate constraints/opportunities analysis

• the ability to evaluate metallic materials and manufacturing processes in order to independently arrive at the selection and optimization of the most suitable process and materials

• the use of numerical methodologies for the analysis of chip removal processes

• the ability to use statistical methods for quality control

• the ability to solve process scheduling problems

Course Structure

frontal or remote lessons

For each module, the development of application cases is envisaged using Excel and VBA

Required Prerequisites

Knowledge of basic mathematical notions is required for the calculation of derivatives and integrals

Attendance of Lessons

Pursuant to art. 27 - Attendance of training activities of the University Teaching Regulations (RDA), attendance is mandatory. The student is required to attend at least 70% of the hours of each individual course, without prejudice to the provisions of art. 30 - Students, workers, athletes, in vulnerable situations, with disabilities and in a state of detention of the RDA

Detailed Course Content



Part 1


Part 2

Metal cutting

Part 3

Statistical process control

Part 4

Process Planning

Textbook Information

  1. M. P. Groover Fundamentals of Modern Manufacturing Wiley
  2. Montgomery, Introduction of Statistical Quality Control
  3. Bozarth, Introduction to Operations And Supply Chain Management, Pearson

Course Planning

 SubjectsText References
1Modulo 1 Metal Casting1
2Modulo 2 Material rmoval processes1
3Modulo 3 Quality management2
4Modulo 7 Production planning3

Learning Assessment

Learning Assessment Procedures

The exam is only written with quantitative and non-quantitative questions. The test lasts 120 minutes. Usually 9 questions. Each question is associated with a maximum score. The overall grade is the sum of the scores for the individual questions. Scores are announced at the beginning of the assignment. At the end of the course, training tests for the exam task are carried out.

Examples of frequently asked questions and / or exercises

1 Indicate with a indicate with drawings the steps in the production sequence in Permanent-­‐Mold Casting Processes.


2 Indicate at least 4 characteristics for the design of the pattern.


3. Indicate the difference between turning and orthogonal cutting. Drawn the two operation and sign the parameters.


4 Indicate at least 4 characteristics of the materials for turning tools.

5 Indicate the meaning of ARL1, show the calculus with the formula and a drawn.

 6 Indicate the criteria to select the deep of cut


7 A cylindrical roughing of 50 steel bars must be performed on the lathe. The caratheristics of the bar: length 500 mm, diameter 134 mm, final diameter 130 mm, Kso 1200, z 0.197, angle of attack ꭓ= 90. The absorbed power is equal to 6 KW. The tool change time is 5 min (C 350 m / min, n 0.25) Calculate the the total minimu time to perform all bars and the total energy consumed.

Considering the  cavity in figure calculate
4a a
the time to fill
the time to solidification
the dimension of the casting
Mold constant Cm0,01min/mm^2
Area on the base of the sprueAb180,00mm^2
Solidification shrinkage 0,03%
Cooling shrinkage 0,01%
Gravitational accelerationg9.816,00mm/s^2
Sand castingn2,00 

9 In a manufacturing process, the upper natural tolerance limit is 118, while UCL is 109. The sample size for constructing the control chart is 4. The specification limits are set at 116 and 95. Calculate

The defective as ppm

Process capability

The new conditions of defective as  ppm for cp=1,5