PE8_9 Production technology, process engineering

ERC 3rd level Code

Research Activities

The TRASFORMA laboratory network includes laboratories of the Polytechnic of Bari, the University of Salento and the National Research Council. The network concentrates skills and equipment for the production of components in light metal alloys of complex shape and / or with locally defined thickness and / or strength characteristics. The laboratory network aims to be a valid point of reference for the industrialization of innovative hot forming processes (based on the use of flexible media such as oil and gas), aimed at the production of components in light metal alloys, which represent today one of the most effective methods to meet the need to lighten up many industrial sectors, such as the automotive, aeronautical, sports and electronic sectors. In order to produce components not only of complex shape, but also with specific and local characteristics of thickness or resistance, the network is equipped with measuring equipment and instruments aimed at the study of sheets of different thickness and / or material (TWB) and control of the friction forces at the interface between material and mold (in order to guide the flow of the material in deformation) through a coating with thin films of hard, wear-resistant material with low friction coefficient.



The TRASFORMA laboratory network includes laboratories of the Polytechnic of Bari, the University of Salento and the National Research Council. The network concentrates skills and equipment for the production of components in light metal alloys of complex shape and / or with locally defined thickness and / or strength characteristics. The laboratory network aims to be a valid point of reference for the industrialization of innovative hot forming processes (based on the use of flexible media such as oil and gas), aimed at the production of components in light metal alloys, which represent today one of the most effective methods to meet the need to lighten up many industrial sectors, such as the automotive, aeronautical, sports and electronic sectors. In order to produce components not only of complex shape, but also with specific and local characteristics of thickness or resistance, the network is equipped with measuring equipment and instruments aimed at the study of sheets of different thickness and / or material (TWB) and control of the friction forces at the interface between material and mold (in order to guide the flow of the material in deformation) through a coating with thin films of hard, wear-resistant material with low friction coefficient.

Department

luigi.tricarico@poliba.it

Contact Person

Luigi Tricarico

Link to laboratory

AF&M-lab (Poliba)

High Power Fiber laser Lab (CNR-IFN)

Tribolab (Poliba)

Forming Research Lab (Unisalento)

SESTANTE Lab

michele.dassisti — Tue, 12 Feb 2019 09:05:29 +0000

SESTANTE Lab michele.dassisti Tue, 02/12/2019 - 10:05

Lab full name

Levantine Lab for Sustainable technologies

ERC 2nd Level Code

ERC 3rd level Code

PE8_11 Sustainable design

Research Activities

The strong commitment of Politecnico di Bari towards manufacturing sustainability deploys into
the proactive promotion of social involvement of its students into the sustainability topics. The
long experience on-the-field led to build up a multidisciplinary laboratory for the promotion and
development of manufacturing sustainability both in research and teaching.
The services offered are directed toward students and/or teachers as well as outside Politecnico
(research and third mission) toward manufacturing companies.
The main services are: analysis for optimisation of manufacturing processes and sustainability
improvement in manufacturing and production systems. Labs are oriented to let the student
gain critical skills on recognising, measuring and applying sustainable solutions to different
manufacturing processes.
Strong competences are available on the analysis of complex real production systems, on the use of
advanced methodologies and non-conventional tools for designing and implementing continuous process actions.

Department

michele.dassisti@poliba.it

Contact Person

Michele Dassisti

Companies and Institutions

ILVA s.p.a. (Taranto)

Bosch T.D.It (Bari)

Masmec (Bari)

Mermec (Monopoli)

Getrag (Bari)

Fantini (Lucera e Terlizzi)

Buzzi Unicem (Barletta)

IVECO (Foggia)

ALENIA (Foggia)

Natuzzi (Santeramo)

Cofra (Barletta)

FIAT Iveco (Foggia)

Om-Pimespo (Bari)

Magneti Marelli (Bari)

Procter&Gamble (Campobasso)

GEDI Costruzioni S.r.l. (Altamura)

Intini Legnami (Noci)

Tubinsud (Bari)

SIEMENS (Pisa)

Tecnomec Enginnerign s.r.l (Altamura)

Mobilturi (Bari)

Bawer (Santeramo)

Master Italy (Conversano)

TERA (Conversano)

VANPLAST (Trani)

COFRA (Barletta)

Globeco (Molfetta)

Apulia Strech (Martina)

Brovedani (Modugno)

Gruppo Turi (Modugno)

Facilities

Load simulator

Portable cryogenic conditioning system, with liquid nitrogen supply for sustainable manufacturing processes

Three-phase transformer

Statistical and calculation software

Services

Optimization systems for the management of cutting tools

Energy analysis for the sustainable optimization of production and technological processes

Design of production management systems for mass customization

Energy production systems from hybrid renewable sources

Flow-type energy storage systems

Redesign of production systems in a lean-six sigma perspective

LLT Lab

sabinaluisa.campanelli — Tue, 12 Feb 2019 08:50:56 +0000

LLT Lab sabinaluisa.ca… Tue, 02/12/2019 - 09:50

Lab full name

Laboratory of Manufacturing Processes by Laser Technologies

ERC 2nd Level Code

ERC 3rd level Code

Research Activities

Since 2007, the Laboratory of Manufacturing processes by Laser Technologies (LLT) of Politecnico
di Bari has been working on Laser Additive Manufacturing processes of metals and on laser
micro-machining.
The laboratory currently houses a Selective Laser Melting (SLM) and a Laser Metal Deposition
machine, able to process metal powders. Both techniques are solid freeform fabrication processes
where 3D parts can be fabricated layer by layer by fusing metal powders with a high energy laser
beam.
SLM machine is equipped with a nanosecond Nd:YAG laser source with a maximum power of 100
W and a scanning head with deflecting mirrors to direct the laser beam over the powder platform.
The laser can operate in both continuous and pulse mode.
In continuous mode, it allows the selective laser sintering and selective laser melting of metal powders; in pulsed mode, it is able to fabricate micro-components by laser ablation, with a pulse
width in the nanosecond range and a repetition rate between 0 and 65kHz. Materials that can be
processed by selective laser melting are mainly steels. On the other hand, it is possible to treat
different materials (steels, titanium alloys, aluminum alloys, ceramics, glass, etc) by means of laser
micro-machining.
LMD machine is characterized by a 5-axis movement system and by an inert chamber that allows
processing several materials including reactive metals such us titanium and aluminum alloys.
LMD is used for solid freeform fabrication and for laser cladding.
The main research topics carried out in the laboratory are:
• Study and characterization of materials obtained by Selective Laser Melting and Selective
Laser Sintering
• Manufacturing of hybrid structures and porous structures with controlled density by Selective
Laser Melting
• Thermal treatments of sintered materials
• Laser surface processing of metals and glass
• Repair of aeronautic components by Laser Metal Deposition
• Freeform fabrication of complex geometries by Selective Laser Melting and Laser Metal
Deposition
• Laser Metal Deposition of WC by Functionally Graded Materials technique
• Development of numerical and analytical models for process optimization

Department

sabinaluisa.campanelli@poliba.it

Contact Person

Sabina Luisa Campanelli

Companies and Institutions

Ge Avio

Elfim srl

Università di Salerno

Facilities

Laser Nd: YAG Rofin Power line Q-switched (100 W in CW and 20 W in PM)

Sintering and laser melting system for metal powders

Laser ablation system

Oven for heat treatments

Micro and macro-hardness machines

Metallographic embedding and polishing machine

Services

Optimization and development of Laser Additive Manufacturing Technologies (Sintering and Selective Laser Melting of metal powders, Laser Cladding and multi-layer laser cladding)

Laser micromachining

Creation of prototypes and metal components with complex geometry.

SD&TM Lab

umberto.galietti — Wed, 06 Feb 2019 09:16:30 +0000

SD&TM Lab umberto.galietti Wed, 02/06/2019 - 10:16

Lab full name

Structural Diagnostic and Thermal Methods for Experimental Mechanics

ERC 2nd Level Code

ERC 3rd level Code

PE8_11 Sustainable design

Research Activities

The Lab carry on research activities mainly on the following topics:
1.   Structural Diagnostic: traditional applications, new applications and development of new non destructive techniques (Thermal methods –IRT; Ultrasound – UT; magnetic particles – MT; Penetrant – PT; Strain Gauges – SG; Eddy Current - EC; Xrays – only interpretation)
2.   Rapid characterization of fatigue behavior of materials/components with InfraRed techniques
3.   Monitoring of manufacturing (Automated Fiber Placement and technological processes (Friction Stir Welding) and analysis of the process for mechanical behavior of components
4.   Coatings analysis: thickness evaluation, quality of adhesion, non destructive evaluation, tribological characterization (in cooperation with tribolab)
5.   Stress analysis with Thermoelastic Stress Analysis (TSA)
6.   Damage monitoring (Acoustic Emission; Thermography, TSA etc)
7.     Fracture Mechanics

The lab is equipped with all needed and up to date instruments for non destructive testing (3 UT systems with possibility of c-scan, MT, PT, 5 Thermocameras in all possible ranges and performances, Eddy current system with single and differential probes, Strain gauges, hole drilling rosette for residual stresses, etc)
In particular the possibility to use 100kN MTS Hydraulic loading machine with thermal cameras allows the fast analysis of fatigue behavior of various materials (tested for aluminum alloys, titanium alloys, traditional and innovative steels, composites) with fatigue limit evaluation in about 3 days instead of 6-8 weeks need for standard testing. Research carried out in the lab showed the possibility to obtain the entire fatigue curve. Research also focuses on the study of Fracture Mechanics behavior of materials in order to localize the crack tip position and to assess the crack propagation law.
The strong point of the adopted approach is the applicability on operating real and complex shaped components (i.e. FSW welded joints).

The research group was awarded of:
a. AEA Technology award during 1998 International Conference of Experimental Mechanics
b. Innovation Award of ALENIA AERMACCHI 2014 for development of thermographic innovative technique for resin pocket characterization
c. Innovation Award of FINMECCANICA 2014 for development of a system for quantitative measurements of resin pockets.
d. AIAS award 2015 for best paper presented in 2014 conference of Italian Association for Stress Analysis
e. Best Student Paper at 2017 SPIE Conference “Thermosense”

The vision of the lab is that all engineering lab activities has to be properly used in the territory. The effort is to consider always in the development of new application or new technologies the possibility for a proper implementation of the results of the research in production line or product development. The lab cooperates strictly with the spinoff company DES - Diagnostic Engineering Solutions. All activities carried out in the lab are and can be industrialized and customized in proper in line control.
The scientific coordinator registered 4 patents: 2 European related to new instruments for Non Destructive Testing based on thermography and 2 national patent (one for thermography application and one for monitoring blood pressure with a wearable device).
The lab is involved actively in a number of industrial and research projects PON, regional, private.

Department

umberto.galietti@poliba.it

Contact Person

Umberto Galietti

Companies and Institutions

Université Montpellier II – Laboratorie de Mécanique et Genie Civil.-France

Instituto Tecnológico de Aeronáutica-Sao José dos Campos-SP-Brazil Departamento de fisica aplicada I- Escuela de Ingeniería de Bilbao-Spain Universitè Livree de Brussels (Be)

University of Sheffield (UK)

University of Manchester (UK)

Dublin City University (IR)

University of West Scotland (UK)

Onerà (FR)

CIRA (IT)

CETMA (IT)

CNR - ISSIA (IT)

CNR - ITIA (IT)

Università di Palermo (IT)

Università del Salento (IT)

Bosch

Leonardo

CALEF

FIAT Research Centre

Isotta Fraschini

Centro Laser

Master

Analysa

Jonica Impianti

Mermec

Sitec

RFP

ELFIM

ITRIB (ES)

Fraunhofer Institute

General Electric (Nuovo Pignone)

Avio

Facilities

DeltaTherm 1560 by StressPhotonics, InSb detector with 320 × 256 pixels, up to 400 Hz, 3-5 mm, NETD <18mK Flir X6450 sc, InSb detector with 640 × 512 pixels, 125 Hz full frame, 1.5-5 mm, NETDFlir 655 sc, 640x512 microbolometer sensor, 50 Hz full frame, 8-

Flir A20, microbolometer with 320 × 240 pixels, up to 60 Hz, 8-14 mm, NETD <55 mK, complete with zoom and portability kit.

Flir i7, microbolomeric sensor 160x140

Fluke 4180 black body

Hanna HI766B2 type K thermocouples suitable for high temperature measurements

ervohydraulic Traction-Compression loading machine: MTS (Fmax = ± 100kN)

Set of halogen lamps with 500W, 1000W power

Bowens QUADX 3000J flash lamps

IPG laser, Model YLP-1-100-30-30-HC, 1064 nm, 30W

Elite penetrating liquids

Silver Yoke SY1 electromagnetic yoke for magnetoscopy

Wood's lamp

Casoni EEC 35+ BOX eddy current instrument

Metal Scan Sinus ultrasound system with variable frequency between 1.2 -13.1 MHz

CS-5008 acquisition system by Instrumentation device

Agilent 34971 Digital Multimeter

Services

Characterization of materials with accelerated methods (thermographic);

Non-destructive tests with PT, MT, UT and TT techniques.

Fatigue damage analysis with thermographic techniques.

Thermo-Physical Lab

roberto.spina — Tue, 05 Feb 2019 11:41:24 +0000

Thermo-Physical Lab roberto.spina Tue, 02/05/2019 - 12:41

Lab full name

Laboratory for the thermo-physical characterization of manufactured polymers

ERC 2nd Level Code

ERC 3rd level Code

Research Activities

The main topics of basic and applied research are related to the technological characterization of polymeric materials, numerical simulation of injection molding processes and the experimental study tensions induced crystallization. Available instruments in the laboratory are a Differential Scanning Calorimetry (Neztsch Pegasus 404 F3), Dilatometer (Netzsch DIL 402C), Rotational Rheometer (HAAKE MARS III) and two workstations for heavy duty computation.

Department

Contact Person

Roberto Spina

roberto.spina@poliba.it

Companies and Institutions

BOSCH

CVIT

GE Oil & Gas

Soffigen sr

Facilities

Differential scanning system with double furnace for measuring the thermal properties of polymers and metal powders.

Dilatometer for measuring the thermal expansion properties of polymers and metals.

Modular rheometer with polarized microscope for measuring the rheological properties of polymers.

Services

selection of appropriate materials for applications

mold design of components with complex geometries

resolution of defects and manufacturing problems

process optimization based on potential and application objectives.

CISP Lab

giuseppe.casalino — Tue, 05 Feb 2019 09:32:03 +0000

CISP Lab giuseppe.casalino Tue, 02/05/2019 - 10:32

Lab full name

Laboratory of Intelligent Computation for Manufacturing and Production Systems

ERC 2nd Level Code

ERC 3rd level Code

Research Activities

Simulation models and mathematical programming techniques can deal with manufacturing systems which call for complex decisions concerning daily issues as well as middle and long horizon strategies (e.g. the introduction of new machines, new products, etc.). Among the most recent computing algorithms, artificial and swarm intelligences have demonstrated their capability of solving scheduling, programming, and maintenance problems in manufacturing complex systems.
The team of Laboratory of “Intelligent Computation for Manufacturing and Manufacturing Systems” have matured a considerable experience in resolving optimization problems for advanced technologies like welding and additive fabrication ones, and modelling the overall manufacturing system. The same approach can be potentially applied to a variety of processes that involve low resources availability and necessity of a high degree of efficiency, like processes in the health care systems.
The team can design a screening experiment and explore the process to be simulated by enquire its actors. The information is structured as an input to the process and several solutions are found by means of commercial software and customer programming. Then, they will discuss until the better solution, if not the best, is selected.
The capability of the team embraces also the use of Statistical Process Control (SPC) with the aid of Design of Experiment technique (DoE).

Department

giuseppe.casalino@poliba.it

Contact Person

Giuseppe Casalino

Companies and Institutions

Dublin City University, Dublin (EIRE)

Istituto Italiano delle Saldature, Genova (Italy)

University of West of Scotland, Paisley, (Scotland, UK)

Università di Napoli, Federico II, Napoli, (Italy)

ISI Italia, Grugliasco (To), (Italy)

Facilities

HP Z820 Workstations |16-core Dual Processor Xeon - Matlab full License

Equipments for mechanical and technological characterization of materials

Microsoft Azure platform for Big Data, Internet of Things and Soft Computing

Fortran compiler

Services

Resolution of technical and applicative, experimental and decision-making problems related to industrial production problems, process optimization, prototyping and product innovation, elaboration and analysis of complex data using statistical / probabilistic algorithms and artificial intelligence (machine learning)

Address / How to reach us

Viale Japigia, 182 - 70126 Bari

Hours

from 9.00 to 18.00 after contact by mail

PhySiMaP-Lab

luigi.tricarico — Tue, 05 Feb 2019 07:45:32 +0000

PhySiMaP-Lab luigi.tricarico Tue, 02/05/2019 - 08:45

Lab full name

Physical Simulation of Manufacturing processes

ERC 2nd Level Code

ERC 3rd level Code

Research Activities

The PhySiMaP-Lab is part of the network of laboratories of the research group on Materials and Innovative Technology (SMATIgroup), which work in the scientific Area of Manufacturing Systems and Technologies. The network includes the laboratories of Advanced Forming & Manufacturing, Metallography and Microscopy, Optimization of Manufacturing Processes by Numerical Simulations, and Thermo-Physical Characterization of Post-Formats Polymers. The laboratories of the network are located di the DMMM, Viale Japigia 182 – Bari - Italy
Aim
The PhySiMaP-Lab performs teaching, research and service activities based on the reproduction in a laboratory scale of a real-world manufacturing process or of the end use of a material. Thermal and mechanical cycles are imposed on small samples of the investigated material, using a commercial physical simulator (3185 Gleeble System) or in home designed equipment. The latter are designed integrating and controlling a Universal testing Machine (200kN - INSTRON 4485), a Digital Image Correlation software (Aramis), a gas pressure system and heating devices based on induction heating or electrical resistance heating. Knowledge acquired through this approach have be used in applications concerning process simulation, testing and basic material studies on steels and light alloys (titanium, aluminium and magnesium).
Skills
Supporting the SMATIgroup research activities, in the M&M-Lab have been developed skills on some process simulation applications, like heat treatments, hot deformation, gas forming, post weld heat treatment. Testing applications concern the determination of stress vs. Strain curves in cold, warm and hot condition, Creep/Stress Rupture evaluation, superplastic characterization, weld heat affected zone simulation for weldability assessment, determination of drawability, bendability, stretch-bendability and formability (by Marciniak and Nakazima test) in cold and warm condition (until 300°C). Application in basic materials studies concern work hardening, precipitation hardening and annealing.
Current research activity
Currently, the PhySiMaP-Lab is involved in research activities financed by the Italian Ministry of Education, Universities and Research Government and by private industry, aimed to the (i) experimental validation an the process analysis of new assembly technologies for the lightening of vehicle structures (Single-Side Resistance Spot welding, Friction Stir Spot Welding, Friction Element Welding, fiber laser welding). (ii) hot stamping of advanced high strength steel

Department

luigi.tricarico@poliba.it

Contact Person

Luigi Tricarico

Companies and Institutions

Centro Ricerche Fiat -TO

Fontana Group - LC

Omer -PA

Masinara Spa - Monteveglio (BO)

AZ Perazsole Srl - Carinario (CE)

Getrag S.p.A. - Bari

Borsh - Centro Studi Componenti per Veicoli S.p.A. - Bari

Nuovo Pignone - Bari

Master - Conversano (BA)

MasterLab - Conversano (BA)

Facilities

Physical simulator Gleeble 3185 (DSI)

INSTRON 4485 Universal Testing Machine (Max Force 200 kN)

3D optical deformation analysis system complete with ARAMIS software

Services

Tensile and compression tests at room temperature with the possibility to control the deformation speed

Hot traction and compression tests (Max temperature: 900 ° C) with the possibility to control temperature and / or deformation speed

Hot traction tests (Max temperature: 1700 ° C), at strain rate or constant load growth, even with semi-solid specimen

Tensile tests with the possibility of imposing thermal cycles on the specimen to simulate welding conditions or heat treatments. Formability tests (cold and hot) by means of Marciniak or Nakazima tests

Risultati di ricerca Risultato di traduzione Misura del ritorno elastico di lamiere sottili mediante piegatura a 90° ( Wiping) sia a freddo che a caldo. Prove di piegatura-stiratura ( Stretch-Bending) sia a freddo che a caldo Modifica

Folding tests on three points

Deep drawing (cold and hot)

Idromechanical Deep Drawing (Hydromechanical Deep Drawing)

Biaxial expansion tests using pressurized oil on sheet metal

Expansion tests by gas under hot pressure (Blow Forming)

Tests of thermomechanical treatments for the refinement of the crystalline structure

Surface roughness and profiles

Address / How to reach us

Viale Japigia 182 - 70126 Bari

Hours

from 9.00 to 18.00 after contact by mail

ManOnSim Lab

gianfranco.palumbo — Mon, 04 Feb 2019 10:41:34 +0000

ManOnSim Lab gianfranco.palumbo Mon, 02/04/2019 - 11:41

Lab full name

Optimization of Manufacturing Processes by Numerical Simulations

ERC 2nd Level Code

ERC 3rd level Code

Research Activities

The lab ManOnSim is part of the network of laboratories of the research group on Materials and Innovative Technology (“SMATIgroup”) whose member operate in the scientific area Manufacturing Systems and Technologies (ING-IND/16). The above mentioned network of laboratories is composed by the laboratory of: Advanced Forming & Manufacturing (AF&M-lab), Physical Simulation of Manufacturing processes (PhySiMaP-Lab), Metallography and Microscopy (OMM) and Thermo-Physical Characterization of Post-Formed Polymers. All the laboratories are located in Viale Japigia 182 – Bari – Italy (DMMM).
The lab ManOnSim is equipped with facilities suitable for the numerical simulation of industrial processes, like:
Sheet Metal Forming in warm and hot conditions;
Casting (sand and high pressure);
Surface treatment (laser hardening, laser remelting);
Heat treatment on steels and aluminum alloys;
Multiphysics processes (induction heating, electro magnetic forming, electric heating);
Residual stresses.

A numerical-experimental approach, based on the mechanical and deformative behavior (using the facilities in PhySiMaP-Lab and OMM-lab) and on the following experimental validation (using the facilities in the AF&M-lab), is adopted.
Both the model tuning and the optimal process conditions are obtained using multi objective optimization techniques based on genetic algorithms and the Response Surface Methodology.

Currently in the lab ManOnSim are conducted research activities financed by the Italian Ministry of Education, Universities and Research Government and by private companies aimed at simulating: (i) the SPF process for producing highly customized biomedical Titanium prostheses; (ii) the warm forming process for producing parts for railways applications; (iii) both the local heat treatment and the stamping process of aluminum heat treated blanks.

Department