It is necessary to familiarize the students in 3rd semester of Mechanical Engineering study, field Production Engineering, with primary shaping procedures, metal casting procedures and polymer parts production.

Student responsibilities:

Grading and evaluation of student work over the course of instruction and at a final exam:

Colloquiums or written exam - 90% Oral exam - 10 %

Methods of monitoring quality that ensure acquisition of exit competences:

The interaction with students during class (asking questions) is checked understanding the material and the acquisition of competencies and skills in accordance with the learning outcomes.

Upon successful completion of the course, students will be able to (learning outcomes):

After successful completion of the course, a student will be able to: - List the basic types of polymeric materials - Define the thermal properties of polymeric materials - Explain the behaviour of materials during the tensile test - Group the polymer processing procedures - Explain the polymer processing procedures - Apply acquired knowledge in problem-solving tasks of the polymer processing - Identify the polymer manufacturing process of the actual product. - Classify casting and molding methods according to different criteria - Describe furnaces, foundry machinery and molding lines - Identify and classify casting defects, determine the causes of the defect formation and recommend remedies - Manufacture a mold for sand casting - Identify steps for software solidification simulation

Lectures

1. Introduction and historical development of foundry. Introduction and historical development of polymer parts production (PPP).

2. Mould mixers (types, characteristics), sand transport. Compounding of polymers.

3. Moulding, moulding machines (types, characteristics, construction). Polymers. Theoretical basics of PPP: production and rheological polymer properties.

4. Cleaning, gatting system removing, shotblasting. Sand casting. Thermal properies of polymers.

5. Lost foam, shell and investment casting. Phenomena during flow of polymer melts.

6. Casting quality methods. Casting defects (International clasification of casting defects ATLAS). Continuous procedures of PPP: extrusion.

7. CAD - casting design (casting methods). Continuous procedures of PPP: calendering, coating.

8. Filling and solidification simulation. Cyclic procedures of PPP: casting, rotatiional moulding, compression and transfer moulding.

9. Melt treatment. Cyclic procedures of PPP: injection moulding.

10. Permanent mould and centrifugal casting. Thermoforming procedures.

11. Die casting. Blow moulding.

12. Solidification and feeding. Procedures of production of foamed and reinforced products.

13. Melting furnaces (types, characteristics), charging. Separating, joining and coating procedures.

14. Horizontal gating design. Production of polymer composites.

15. Vertical gating design. Recovery of polymers.

Exercises

1. Green sand moulding.

2. Foundry sand testing.

3. CO2 and shell mould and core making.

4. Permanent mould casting, furnaces, defects.

5. Gating system design, problem solving.

6. Casting design.

7. Filling and solidification simulation.

8. Introduction to polymer processing.

9. Identification of polymer materials.

10. Numerical exercises.

11. Injection moulding procedures.

12. Visit to injection moulding plant.

13. Composites.

14. Thermoforming.

15. Hot-air welding.

Compulsory literature:

B.Bauer, I.Mihalic, Osnove tehnologije lijevanja, skripta, FSB Zagreb, 2012.
Bonačić Mandinić, Z., Budić, I.: Osnove tehnologije kalupljenja, Jednokratni kalupi, I. dio, Strojarski Fakultet, Slavonski Brod.
Raos, P., Šercer, M.: Teorijske osnove proizvodnje polimernih tvorevina, Strojarski fakultet u Slavonskom Brodu, 2010.
Rogić, A., Čatić, I., Godec, D.: Polimeri i polimerne tvorevine, DPG, Zagreb, 2008.

Recommended literature:

Šercer, M., Križan, B., Basan, R.: Konstruiranje polimernih proizvoda, FSB, Zagreb, 2009.