Manufacturing Technologies

Manufacturing Technologies
3 YEAR2 semester9 CREDITS
Prof. Fabrizio Quadrini2019-20
QUADRINI FABRIZIO 2020-21
Code: 8037968
SSD: ING-IND/16

LEARNING OUTCOMES:
Basic knowledge about manufacturing processes for metals.

KNOWLEDGE AND UNDERSTANDING:
Conventional technologies for metals are studied. In order to stimulate student’s knowledge, the interaction between material and tools is always highlighted. The student is able to analyse and evaluate any manufacturing process with a proper technical language.

APPLYING KNOWLEDGE AND UNDERSTANDING:
Thanks to the interaction between frontal lessons and laboratory activities, the student is stimulated to have an own technical profile. He will be able to manage technologies with technical language and sketch capabilities.

MAKING JUDGEMENTS:
The student develops own skills and capabilities in describing transformation processes by taking example from the frontal lessons.

COMMUNICATION SKILLS:
Students are invited to describe technologies in a proper technical way and with an adequate technical speech.

LEARNING SKILLS:
Learning skills are continuously improved thanks to the applied methodology for technology description. This methodology can be translated to any other technological process. Capabilities increase because of the number of described technologies and their correlation. Examples from the industrial world and laboratory experiments crystallize the knowledge about new technologies.

SYLLABUS:

Materials structure and properties: structure of metals, crystals, thermal stresses, solid solution, material properties, mechanical behavior, testing, and manufacturing properties of materials, metal alloys: structure and strengthening by heat treatment

Manufacturing of metals: fundamental of metal-casting, metal-casting processes and equipment, bulk forming (rolling, forging, extrusion and drawing), sheet-metal forming, sintering, fundamentals of machining, cutting-tools, machining processes (turning, drilling, milling).

Joining processes and advanced machining: fusion-welding, solid-state welding, adhesive-bonding, fastening, rapid-prototyping processes and operations, additive manufacturing.

Laboratory lessons: mechanical tests, surface engineering, hardness of metals, microscopy.

Machine Design

Machine Design
3 YEAR2 semester9 CREDITS
Prof. Luciano Cantone2019-20
CANTONE LUCIANO 2020-21
Code: 8037969
SSD: ING-IND/14

OBJECTIVES

LEARNING OUTCOMES: Designing mechanical components considering the need to save weight, material and energy while respecting safety, to promote the usefulness and social impact of the designed product.
KNOWLEDGE AND UNDERSTANDING: The design of mechanical systems; in particular, basic knowledge of the design methodologies of important machine components.
APPLYING KNOWLEDGE AND UNDERSTANDING: Knowing how to recognise, distinguish and use the main techniques and tools for the design of mechanical components.
MAKING JUDGEMENTS: Students must assume the missing data of a problem and be able to independently formulate basic hypotheses (such as that on safety coefficients) based on the operational and functional context of the system/component they have to design.
COMMUNICATION SKILLS: Transfer information, ideas and solutions to specialist and non-specialist interlocutors through intensive use of English terminology.
LEARNING SKILLS: Students, by learning the basics of design, acquire the tools to learn the necessary design techniques of systems/components not directly addressed during the course.

COURSE SYLLABUS

The first part of the course is addressed to the consolidation of basic knowledge to put the student in the right conditions to face a generic machine design problem: Mechanical Engineering design in Broad, Perspective, Load Analysis, Materials, Static Body Stresses, Elastic strain, Deflection, Stability (Eulerian buckling), Vibrations (beam Eigen-modes), Failure Theories, Safety Factors, Reliability, High cycles Fatigue, Low cycles Fatigue, Surface Damage, Contact and impact problems.

The second part will cover specific design activities: Threaded Fasteners and Power Screws, Rivets, Welding, Bonding, Springs, Lubrication and Sliding Bearings, Rolling-Element Bearings, Spur and Helical Gears, Shafts and Associated Parts. During the course, several design activities will be demonstrated by exercises and by real-life applications.

Energy Systems

Energy Systems
3 YEAR1 semester6 CREDITS
Prof. Michele Manno2019-20
MANNO MICHELE 2020-21
Code: 8037964
SSD: ING-IND/09

OBJECTIVES

LEARNING OUTCOMES:
After completing the course, the students should acquire a good knowledge of the fundamental operating principles of energy conversion systems, and they should be able to analyze the layout and evaluate the performance and efficiency of thermal and hydroelectric power plants.

KNOWLEDGE AND UNDERSTANDING:
Students are expected to understand the fundamental principles underlying the operation of energy conversion systems.

APPLYING KNOWLEDGE AND UNDERSTANDING:
Students are expected to be able to assess the performance of energy conversion systems.

MAKING JUDGEMENTS:
Students are expected to be able to choose the most suitable energy conversion system and its operating parameters, given a particular application.

COMMUNICATION SKILLS:
Students are expected to be able to describe and illustrate the operating principles of energy conversion systems.

LEARNING SKILLS:
Students are expected to be able to read and fully understand technical literature related to energy conversion systems.

COURSE SYLLABUS

Students will be introduced to the main principles of energy conversion systems, with particular reference to steam and gas turbine power plants, combined cycle power plants,
hydroelectric power generation.

More specifically, the following topics will be addressed:

Introduction

  • Review of fluid properties and equations of state.
  • Analysis of combustion processes.
  • Analysis of energy conversion systems based on 1st and 2nd Laws of Thermodynamics.
  • Thermodynamic cycles: definition of network output and thermal efficiency; external and internal irreversibilities; efficiency factors.

Steam power plants

  • Analysis of ideal and real thermodynamic cycles.
  • Choice of operating parameters.
  • Techniques to improve plant efficiency: steam reheating, regenerative feed heating.
  • Plant layouts, applications.

Gas turbine power plants

  • Analysis of ideal and real thermodynamic cycles.
  • Choice of operating parameters and techniques to improve performance: regenerative heat exchanger, reheaters, intercoolers.
  • Layout of heavy-duty and aeroderivative turbines, applications.

Combined cycle power plants

  • Analysis of “topping” (gas turbine) and “bottoming” sections, definition of recovery efficiency.
  • Thermodynamic optimization of bottoming sections with variable temperature heat input.
  • Plant layout, applications.

Hydroelectric power generation

  • Hydraulic turbines: classification, operating parameters, performance characteristics.
  • Hydroelectric plant classification and layouts, applications.

Fluid Machinery

Fluid Machinery
3 YEAR1 semester6 CREDITS
Prof. Vincenzo Mulone e
Roberto Verzicco
2019-20
VERZICCO ROBERTO
MULONE VINCENZO
2020-21
Code: 8037967
SSD: ING-IND/08

LEARNING OUTCOMES: This course aims at providing the fundamentals of fluid dynamics applied to fluid machines. More in detail, it deals with the fluid dynamics equations applied to energy-consuming and energy-producing machines, characterized by both axial and radial flows. It also deals with the understanding of systems connected to fluid machines.

KNOWLEDGE AND UNDERSTANDING: The student will be able to develop simple but useful calculations of fluid machines in terms of flow, work and power, along with solving practical problems of interest. The student will also learn the basics of the control of fluid machines with respect to the flow rate, work exchanged and power output or input The knowledge developed will help the student for both the design of fluid machines and of the systems connected to the machines.

APPLYING KNOWLEDGE AND UNDERSTANDING: The student will apply the knowledge and understanding developed to the analysis of practical problems. This would imply critical knowledge in terms of size and power output/input; the same thing will be done for the systems connected to the machine.

MAKING JUDGEMENTS: The student will have to prove his critical awareness with respect to the simplifying assumptions useful to describe and calculate fluid machines, as well as his critical awareness of the correct order of magnitude of performance parameters while dealing or designing fluid machines.

COMMUNICATION SKILLS: The student will prove, mostly during the oral test, his capacity of describing the operation and functioning of fluid machines, convening of the knowledge developed.

LEARNING SKILLS: The student will get familiar with the schematization of practical problems, mostly during the development of his skills for the written test. This mainly concerns fluid machines (e.g. wind turbines, steam turbines, hydraulic turbines, hydraulic pumps, gas compressors, etc) and the systems connected to the machines (e.g. hydraulic power plants, pumping systems, air distribution systems, etc).

DETAILED SYLLABUS  

Introduction 

Classification of machines. Turbines, compressors, volumetric, rotary machines and their applications to industrial practical cases. Analysis of performance: power, specific work, efficiency.

Basics of fluid mechanics 

Material and spatial description of the flow field. Translation, deformation and rotation. Reynolds’ transport theorem. Principles of conservation and balance (mass, momentum, energy, entropy) in differential form. Mass, momentum, thermal and mechanical energy in stationary and rotating frames of reference. 

Basics of fluid mechanics applied to turbomachinery 

Integral balances in turbomachines (mass, momentum, moment of momentum, energy) and basic applications. 
Gas dynamics equations, speed of sound, Mach number. Applications to nozzles in supersonic conditions, normal shock waves. 

Velocity diagrams coupled to stator and rotor blades for energy producing and consuming machines. Moment of Momentum balance. Energy transfer and different expressions of the Euler work. Trothalpy, degree of reaction, utilization for a turbine. 

Applications 

Scaling and similitude: dimensionless parameters, specific speed and diameter, Cordier curve. Scaling and similitude for compressible flow machines. 

Axial turbines: stage analysis, flow and loading coefficients, reaction ratio, special cases of 0 and 0.5 reaction ratio designs. Off-design operation and performance maps. 

Axial compressors: stage analysis, flow and loading coefficients, reaction ratio. De Haller design criterion and its effect on blade design. Off-design operation and performance maps. 

Centrifugal compressors: analysis of velocity diagrams, effect of blade shape on performance maps, stability and efficiency. Slip factor. Vaneless and vaned diffuser. Flow control (variable speed, IGV and throttling). 

Centrifugal pumps operation into systems: definition of head and volumetric flow rate. Head-flow rate performance map and effects on velocity diagrams, blade design and efficiency. System head curves for simple and multi-branched open-ended and closed-circuit systems. Friction factor and expression of dimensional friction losses. Flow control by variable speed and throttling.  

Cavitation: physical description; effects of system design on cavitation, Net Positive Suction Head, suction specific speed.

TEXTBOOKS AND MATERIAL 

S. Korpela. Principles of Turbomachinery, Wiley 2019. 

Karassik et al., Pump handbook, McGraw Hill. 

Powerpoint slides and videos are available on the MS-team website.