Rodolfo FRANCHI

Rodolfo FRANCHI

Ricercatore Universitario

Dipartimento di Ingegneria dell'Innovazione

Centro Ecotekne Pal. O - S.P. 6, Lecce - Monteroni - LECCE (LE)

Ufficio, Piano terra

Rodolfo Franchi obtained in 2014 the Mechanical and Industrial Engineering Ph. D. at the University of Salento, he is a Researcher of the ING-IND/16 Scientific-Disciplinary Sector, entitled "Technologies and Manufacturing Systems". Its main areas of competence are related with manufacturing processes analysis and optimization with specifics focus on machining of aeronautics and aerospace superalloys and on Tool Condition Monitoring in metal cutting.

Curriculum Vitae

During his scientific career, Rodolfo Franchi has gained experience in the research area related to the study of manufacturing processes, with specific focus on those regarding aeronauticals and aerospace materials.

In particular, the research fields in which he is currently mainly active are focused on the following topics:

• Development of reliables numerical models for the simulation of machining processes, forging processes, heat treatments and machining distortions, with specifics focus on difficult-to-machine materials;

• Experimental analysis of machining, with particular focus on cutting forces, temperatures, surface quality and tool wear, under differents cutting conditions (cutting speed, feed, depth of cut, type of lubrication, etc.);

• Analytical tool wear modeling as a function of the cutting conditions;

• Product / Process optimization through CAD/CAE/CAM integration and the development of process automations;

• Study and development of systems for Tool Condition Monitoring in machining.

Didattica

A.A. 2021/2022

ADVANCED TECHNOLOGIES AND ADDITIVE MANUFACTURING FOR AEROSPACE

Degree course AEROSPACE ENGINEERING

Course type Laurea Magistrale

Language INGLESE

Credits 9.0

Owner professor RODOLFO FRANCHI

Teaching hours Ore totali di attività frontale: 81.0

  Ore erogate dal docente RODOLFO FRANCHI: 54.0

Year taught 2021/2022

For matriculated on 2020/2021

Course year 2

Structure DIPARTIMENTO DI INGEGNERIA DELL'INNOVAZIONE

Subject matter CURRICULUM AEROSPACE TECHNOLOGY

Location Brindisi

Torna all'elenco
ADVANCED TECHNOLOGIES AND ADDITIVE MANUFACTURING FOR AEROSPACE

Degree course AEROSPACE ENGINEERING

Subject area ING-IND/16

Course type Laurea Magistrale

Credits 9.0

Owner professor RODOLFO FRANCHI

Teaching hours Ore totali di attività frontale: 81.0

  Ore erogate dal docente RODOLFO FRANCHI: 54.0

For matriculated on 2020/2021

Year taught 2021/2022

Course year 2

Semestre Secondo Semestre (dal 01/03/2022 al 10/06/2022)

Language INGLESE

Subject matter CURRICULUM AEROSPACE TECHNOLOGY (A101)

Location Brindisi

You must have passed the Examination of Mechanical Technology. The contents of the Industrial Design Drawing and knowledge of Technical Industrial Design are also useful.

The course aims to deepen the aspects related to manufacturing technologies applied in aeronautical constructions, with particular reference to the materials selection and application and the related transformation technologies. Materials/technologies solutions will mainly be used for the construction of airframe and motor structures. The aspects of the "Machinability of materials for aeronautical application" in terms of cutting processes will be discussed. The study and the classification of light alloys for aeronautical application, as well as superframes for airframe and motor application, will be addressed. In particular, the main aspects related to the metallurgy and workability of Alluminum alloys and Nickel and Titanium superalloys will be studied taking into account the comparison with real applications. In the field of plastic deformation technologies, the basic principles of Super Plastic Forming and its applicability to the aeronautics industry will be illustrated. At the same time, aspects regarding assembly operations will be dealt with, in particular those relating to welding of metal materials and the riveting of components. We will then proceed to a technology analysis of the application of composite materials to the aeronautical sector. On some aspects discussed in the theory section, numerical exercises will be carried out to familiarize with the physical quantities that characterize them and laboratory exercises will be focused on Finite Element simulation tools for the machining and forging processes. Moreover, the course aims to provide an overview of Additive Manufacturing processes, explain their underlying physical principles, discuss current research and an appreciation for why AM is so important to many branches of industry. In order to take maximum advantage from the capabilities of additive metal technology in the most economical way, will be studied how to design for this technology by following its principles. At the same time, the aspects relating to the design for additive metal manufacturing (DFAM) concept and, the act of integrating product design and additive manufacturing principles into one activity, will be illustrated. Laboratory exercises will be carried out by 3D printer with FFF (Fused Filament Fabrication) and Wax Jet Printing technology, in addition to laboratory exercises that will be focused on tools for the finite element simulation of additive processes.

During and a the end of the course, the student should be able to acquire:
- An in-depth knowledge of materials for aeronautical application and processes for their transformation;
- A basic knowledge of the Alluminum alloys, Nickel and Titanium superalloys characterization;
- A basic knowledge of the Additive Manufacturing Technologies in terms of characterization and use;
- A basic knowledge of composite materials use for aeronautical applications;
- A basic knowledge of the Finite Element manufacturing processes simulation with specific focus on machining and forging.
- Knowledge for characterization and use of Additive Manufacturing technologies.
- Basic knowledge of Design for Additive Manufacturing.
 

Attività frontale di 81 ore.

Written, oral, written and/or oral.
The exam consists of two consecutive parts:
- A first written part (its duration is about 1 hour) in which the student have to solve a task related to the topics discussed in the course; the test aims to determine the student's ability to carry out calculations related to the physical quantities that characterize the processes discussed during the course;
- The second oral part (which begins immediately after the written part) in which the student discusses both the written part and other contents of the course, in order to illustrate their understanding and knowledge level of the topics discussed and the ability to deliver it to perform relevant kinematic and dynamic analyzes.
 

- Critical analysis of aeronautical materials/processes for comparison with the reference context (9 hours). Tutorials on the discussed topics (3 hours).

- Machining of materials for aeronautical applications (9 hours). Exercises on the discussed topics (6 hours).
- Further research on the metallurgy of light alloys, Nickel superalloys and Titanium alloys (9 hours).
-  Aeronautical components junction technologies: welding and riveting (6 hours).
- Super Plastic Forming technology (3 hours).
- Critical analysis of the composite materials applications and their transformation technologies for aeronautics applications (3 hours).
- Finite Elements simulation applied to the machining and forging (6 hours) and their application to some cases of study (6 hours).
- Additive manufacturing production (3 hours).
- Classification of additive manufacturing processes (3 hours).
- Overview of existing manufacturers and their specific equipment (3 hours).
- Additive manufacturing technologies for metallic materials: METAL POWDER, METAL WIRE, METAL SHEETS (3 hours).
- Powder Fusion Mechanisms (solid-state sintering, chemically-induced binding, liquid-phase sintering, full melting) (3 hours).
- AM technologies for plastic component production (powder, solid and liquid material) (3 hours).
- Design for Additive Manufacturing, Additive Manufacturing Process Steps (3 hours).
- Additive manufacturing technologies and applications in the aerospace industry (3 hours).
- Finite element simulation techniques for additive manufacturing and its application to case studies (3 hours).

Small time remodeling is possible between the subjects treated according to the course progress.

[1] F.C. Campbell, Manufacturing Technology for Aerospace Structural materials, First Edition, Elsevier, 2006
[2] M. Donachie, S. Donachie, SuperAlloys a Technical Guide, UniSalento, Second Edition, ASM International, 2002.
[3] Additive Manufacturing  - Innovations, Advances, and Applications, T.S. Srivatsan, T.S. Sudarshan.
[4] Dispense del Corso.

ADVANCED TECHNOLOGIES AND ADDITIVE MANUFACTURING FOR AEROSPACE (ING-IND/16)

Pubblicazioni

  1. A. Del Prete, A.A. De Vitis, R. Franchi “Numerical-experimental correlation of distortions induced by machining process on thin-walled nickel super alloy forged components”, Procedia 15th Esaform Conference (2012) 1299-1304, Published by Key Engineering Materials Vols. 504 – 506, Part 2, ISBN: 13 978-3-03785-366-5, ISSN: 1013-9826
  2. A. Del Prete, T. Primo, R. Franchi, “Super-Nickel Ortogonal Turning Operations Optimization”, Procedia CIRP 8 (2013) 164 – 169, Published by Elsevier B.V., 14th CIRP Conference on Modelling of Machining Operations (CIRP CMMO) ISSN: 2212-8271
  3. A. Del Prete, R. Franchi, A. Spagnolo “Wearing Evaluation in nickel super-alloys turning for the development of a predictive model for CAM Optimization”, 17th ESAFORM (2014), Published by Key Engineering Materials Vols. 504 – 506, Part 2, ISBN: 13 978-3-03785-366-5, ISSN: 1013-9826
  4. A. Del Prete, R. Franchi, E. Mariano “Nickel Super Alloy components Surface Integrity Control through Numerical Optimization”, 17th ESAFORM (2014), Published by Key Engineering Materials Vols. 504 – 506, Part 2, ISBN: 13 978-3-03785-366-5, ISSN: 1013-9826
  5. D. Umbrello, A. Del Prete, R. Franchi, M. Alfano, G. Rotella, L. Filice (2014) “Analisi dell’integrità superficiale durante i processi per asportazione di truciolo su Waspaloy” Atti del 3° Congresso Nazionale del Coordinamento della Meccanica Italiana, 30 Giugno-1 Luglio 2014, paper N° 63, Proceedings su CD (ISBN 88-902096-2-3)
  6. R. Franchi, A. Del Prete, G. Papadia, A numerical procedure for machining distortions simulation on a SAF 2507 casting workpiece 18th ESAFORM (2015), Key Engineering Materials Vols 651-653 (2015) pp 1241-1246, ISSN: 1662-9795
  7. R. Franchi, A. Del Prete, T. Primo, The use of FEA in the simulation of a metal cutting operations in the presence of random uncertainty, 18th ESAFORM (2015), Key Engineering Materials Vols 651-653 (2015) pp 1247-1254, ISSN: 1662-9795
  8. R. Franchi, A. Del Prete, D. Umbrello, E.Mariano, Inverse Analysis Procedure to Determine Flow Stress and Friction Data for Metal Cutting Finite Element Modeling, 18th ESAFORM (2015), Key Engineering Materials Vols 651-653 (2015) pp 1345-1450, ISSN: 1662-9795
  9. R. Franchi, A. Del Prete, E. Mariano, An inverse analysis application for optimal modelling of friction conditions in metal cutting processes, AITEM 2015
  10. R. Franchi, A. Del Prete, D. Umbrello, Inverse analysis procedure to determine flow stress and friction data for finite element modeling of machining, International Journal of Material Forming, October 2017, Volume 10, Issue 5, pp 685–695, DOI 1007/s12289-016-1311-x
  11. A. Del Prete, R. Franchi, L. Filice, D. Umbrello, S. Caruso, S. Rinaldi, Machinability of Nickel Superalloys under Different Cutting and Lubri-Cooling Conditions, AITEM 2017
  12. S. Rinaldi, S. Caruso, D. Umbrello, L. Filice, R. Franchi, A. Del Prete, Machinability of Waspaloy under different cutting and lubri-cooling conditions, in press on International Journal of Advanced Manufacturing Technology (2017), (DOI 10.1007/s00170-017-1133-0)
  13. R. Franchi, A. Del Prete, , I. Donatiello, M. Calabrese, Ring Rolling Process Simulation For Microstructure Optimization, 20th ESAFORM (2017), AIP Conference Proceedings 1896, 100005 (2017), https://doi.org/10.1063/1.5008123
  14. S. Caruso, S. Rinaldi, R. Franchi, A. Del Prete, D. Umbrello, Experimental Analysis of Influence of Cutting Conditions on Machinability of Waspaloy, 20th ESAFORM (2017), AIP Conference Proceedings 1896, 090008 (2017), https://doi.org/10.1063/1.5008115
  15. R. Franchi, A. Del Prete, I. Donatiello, M. Calabrese, Ring Rolling Process Simulation For Geometry Optimization, 20th ESAFORM (2017), AIP Conference Proceedings 1896, 190010 (2017), https://doi.org/10.1063/1.5008123
  16. R. Franchi, A. Del Prete, M. Calabrese, I. Donatiello, Numerical Simulation of Machining Distortions on a Forged Component Obtained by Ring Rolling Process, AIP Conference Proceedings 1896, 090002 (2017), https://doi.org/10.1063/1.5008109
  17. S. Imbrogno, S. Rinaldi, D. Umbrello, L. Filice, R. Franchi, A. Del Prete, A physically based constitutive model for predicting the surface integrity in machining of Waspaloy, Materials and Design 152 (2018) 140–155, https://doi.org/10.1016/j.matdes.2018.04.069
  18. F.P. Pinnola, G. Zavarise, A. Del Prete, R. Franchi, On the appearance of fractional operators in non-linear stress–strain relation of metals, International Journal of Non-Linear Mechanics 105 (2018) 1–8, https://doi.org/10.1016/j.ijnonlinmec.2008.001
  19. A. Del Prete, R. Franchi, D. De Lorenzis, Optimization of turning process through the analytic flank wear modelling, AIP Conference Proceedings 1960, 070008 (2018), https://doi.org/10.1063/1.5034904
  20. A. Del Prete, R. Franchi, F. Antermite, I. Donatiello, Numerical simulation of machining distortions on a forged aerospace component following a one and a multi-step approach, AIP Conference Proceedings 1960, 070009 (2018), https://doi.org/10.1063/1.5034905
  21. A.Del Prete, R. Franchi, S. Cacace, Q. Semeraro, Optimization of cutting conditions using an evolutive online procedure, Journal of Intelligent Manufacturing, (2019), https://doi.org/10.1007/s10845-018-01460-x
  22. A. Del Prete, R. Franchi, A. Begher, Development Of A Numerical Model For The Cryogenic Machining Simulation Applied To A Nickel Superalloy, AIP Conference Proceedings 2113, 080018 (2019); https://doi.org/10.1063/1.5112626
  23. A. Del Prete, R. Franchi, F. Antermite, I. Donatiello, Development of an automatic procedure for machining distortions improvement on an aeronautic axisymmetric component, AIP Conference Proceedings 2113, 080008 (2019); https://doi.org/10.1063/1.5112616
  24. R. Franchi, M. Giannuzzi, G. Papadia, Thermal characterization methodology for dry finishing turning of SAF 2507 stainless steel based on finite element simulations and surrogate models, Procedia CIRP 00 (2019) 000–000