Advanced Manufacturing Processes (AMPs)

Introduction to AMPs

by Dr. Sunil Pathak Faculty of Engineering Technology [email protected]

Intro to AMP by Dr. Sunil Pathak Chapter Description

• Aims – To provide and insight on advanced manufacturing processes – To provide details on why we need AMP and its characteristics

• Expected Outcomes – Learner will be able to know about AMPs – Learner will be able to identify role of AMPs in todays sceneries

• Other related Information – Student must have some basic idea of conventional manufacturing and – Student must have some fundamentals on materials

• References – Prof N K Jain (IIT Indore, Lecture Notes) – Prof. V K Jain (IIT Kanpur, Lecture Notes)

Intro to AMP by Dr. Sunil Pathak Materials Used In Engineering Applications

Metal and its Alloys Plastics and Composites Ceramics

Engineering Materials • Getting More Popularity Having Much Superior • Definite Advantages Over Others Properties

• Ultra High Strength, Hardness HOW TO MACHINE Very High Temperature THEM Resistance ? • Difficult To Machine By SOLUTION Conventional Machining Methods Advanced Manufacturing/Machining Processes Courtesy: Prof. N K Jain (IIT Indore, India) Intro to AMP by Dr. Sunil Pathak Need of Advanced Manufacturing/Machining Processes • Limitations of conventional machining methods (workpiece hardness, surface roughness, 3-d parts and complex geometries)

Increased Workpiece Hardness

Decreased Economic Cutting Speed

Lower Productivity

• Rapid Improvements InThe Properties Of Materials (Workpiece Hardness, Strength, Etc.)

• Metals & Non – Metals : Stainless Steel , High Strength Temperature Resistant(hsrt) Super Alloys: Stellite, Incoloys Etc.

• Tool Material Hardness >>Workpiece Hardness . Requires Much Superior Quality Of Tool Materials Intro to AMP by Dr. Sunil Pathak Courtesy: Prof. N K Jain (IIT Indore, India) Need Of Product Requirements

Advanced . Complex Shapes Manufacturing/ High Production Rate While Processing Difficult –To- . Machining In Inaccessible Areas Machining Machine Materials Processes . Low Tolerances (Say, 10 µm) Low Cost Of Production Precision ?? And Ultra precision Machining (Nano-meter Machining)

. Better Surface Integrity (No Surface Defects, Etc.) Requires Material Removal In The Form Of Atoms And / Or Molecules . High Surface Finish (Nano Level Ra Value =>Nm)

. Miniaturization Of Products (Examples: Landline Phone & Mobile, Old Computers & Lap Top, Etc.) ADVANCED MACHINING PROCESSES (Amps) . High Mrr

Intro to AMP by Dr. Sunil Pathak Courtesy: Prof. N K Jain (IIT Indore, India) Behaviour and Manufacturing Properties of Engineering Materials

Structure Physical and Mechanical Property of Chemical Properties Modification Material Properties Strength  Heat  Ductility   Melting Point Treatment Atomic Bond:  Elasticity  Metallic,  Density Annealing   Stiffness  Tempering Ionic,Covalent Specific Heat   Hardness  Normalizing  Crystalline Thermal  Toughness  Conductivity  Hardening Amorphous  Fatigue   Thermal  Alloying or Creep  Non-Crystalline Expansion  Reinforcement s Resistance to  Composites  Partly Crystalline  Electrical Wear, Conductivity  Laminations  Polymer Chains Corrosion,   Magnetic Oxidation Fillers Properties  Hot Hardness  Surface  Oxidation and Strength Treatment  Corrosion

Intro to AMP by Dr. Sunil Pathak Courtesy: Prof. N K Jain (IIT Indore, India) [1] CLASSIFICATION OF VARIOUS MANUFACTURING PROCESSES Basic Advanced or Unconventional Nature Traditional or Conventional Processes Processes Primary and Molding Processes Rapid Prototyping Processes Forming [After 1990] Processes Single-Use or Multiple-Use Mold Liquid Based Solid Based Powder Casting Based Expendable Mold Casting [Additive Or Multiple-use Single-use Permanent Mold SLA, FDM, SLS, Accretion: Pattern Pattern Casting: Slush SLT, SGC, LOM, BPM, Create Shape casting, TDP, From Molten, Corthias Casting Low- SOUP, MJM, MJS, Gaseous, or SCS,etc. SAHP,etc. DSPC, Solid Particles] pressure Vacuum Casting etc. Sand Casting, Investment Casting, Squeeze For Fabrication of Polymers: Thermoforming, Casting, , Blow, Compression, Injection, Reaction Plaster Mold Casting, Centrifugal Casting, Injection, Transfer, Cold, Rotational, & Foam Ceramic Mold Full-mold Casting, Molding, Calendering, Spinning, Dipping, etc. Casting, and Lost- Semicentrifugal For Fabrication of Ceramics: Blow Molding, Dry Rubber Mold Foam Casting Pressing, Isostatic Pressing, Slip Casting, Plastic Casting, Casting Centrifuging Casting, FormingTechniques Graphite Mold Casting, Continuous Casting, For Fabrication of Fiber Reinforced ElectromagneticOr Composites: Pultrusion, Filament Winding, Shell Molding, Levitation Casting Vacuum-bag and Pressure-bag Molding, Resin- Powder Processes [Late Nineteenth transfer Molding, Spray Molding, Sheet Stamping, Century] Braiding, 3D- Knitting &Weaving,Intro to AMP by Dr. Sunil Pathak [1] CLASSIFICATION OF VARIOUS MANUFACTURING PROCESSES (Cont…)

Basic Advanced or Unconventional Nature Traditional or Conventional Processes Processes Deforming Metal Advanced Metal Forming Processes Processes Hot- Cold-working Processes High Energy Rate Forming (HERF) working Processes: [Formative: , Squeezing: Cold Rolling, Cold , , Explosive Shapes The Forging, Cold Extrusion, , Sizing, Riveting, Forming, and Electro-hydraulic Material In Staking, , Peening, Burnishing, Extrusion, Forming. Laser Bending, Solid State Hubbing, and Thread Rolling. Using Property Hot- Bending: Angle Bending, Roll Bending, 3d-laser Forming, , Of Draw and Compression Bending, Roll- Hot Isostatic Pressing (HIP) Plasticity.] Piercing forming, Seaming, Flanging, and Straightening. For Components: Shearing: Slitting, Blanking, Piercing, Lancing, Perforating, Notching, Nibbling, Electroforming, Plasma Spray Shaving, Trimming, Cutoff, and Dinking. Forming Drawing: Spinning, Embossing, Stretch Forming, and Ironing

Sheet-metal Forming Operations Intro to AMP by Dr. Sunil Pathak Courtesy: Prof. N K Jain (IIT Indore, India) [1] CLASSIFICATION OF VARIOUS MANUFACTURING (Continued)

Basic Traditional or Conventional Processes Advanced/Unconventional Processes Nature Material Conventional Machining Processes AMPs [After 1945] Removal Processes [19th Century Onwards] Axi-symmetric Prismatic General Mechanical Chemical Electro- Thermal Parts Parts chemical Subtractive : Shape the Turning, Milling, Sawing, USM, CHM, ECM EDM Product by Facing, Shaping, Broaching, AJM, PCM, EBM Removing the Excess TaperTurning, Planning, Hobbing, WJM, TCM LBM Material] etc. Threading, Grinding, AWJM, IBM Drilling, Boring, Honing, IJM, PAM Reaming, etc. Lapping, AFM, etc. MAF, MRF Intro to AMP by Dr. Sunil Pathak [1] CLASSIFICATION OF VARIOUS MANUFACTURING (Continued) Joining Processes Joining Mechanical Bonding Atomic Bonding Advanced Or Tempor Permanent Solid Liquid state or Fusion Solid/ Consolidation - ary or semi- state Welding Liquid Techniques: Or permanent welding Electrical Chemical state EBW, Fabrication LBW, Thread Rivets, Friction, Arc welding: Gas , Processes USW joints Stitches, Forge, Using Consumable welding: , Welding of Staples, Diffusion Electrode SMAW, OAW, and and [For assembling Plastics Shrink-fits, welding, GMAW, FCAW, PGW, Adhesive the various (only for SAW; Thermit bonding component s Thermoplastics) Cold Those using welding of a product] :USW, Welding: Non- consumable LBW, Pressure, Electrode: GTAW, Friction/spin Welding Explosive, PAW, VibrationWelding Ultrasonic SW. Friction stir Welding Resistance welding welding: RSW, Hot-plate welding RSEW, Hot-gas welding RPW. Implant welding Infrared welding Induction IntroMicro to AMP- waveby Dr. Sunil welding Pathak Courtesy: Prof. N K Jain (IIT Indore, India) welding [1] CLASSIFICATION OF VARIOUS MANUFACTURING (Continued)

Basic Advanced or Nature Traditional or Conventional Processes Unconventional Processes Heat Laser Beam Hardening and Treatment SURFACE HARDENING (ie Selective or Bulk Heating) Processes: Flame Hardening, and Electron Beam Hardening Induction Hardening Property Enhancing CASE HARDENING (ie Surface Chemistry Additional Layer Processes HARDENING Altering) Processes: Carburizing (pack, gas, and Depositing: Ionitriding, Ion TECHNIQUES liquid type), Nitriding, Cyaniding or Carburizing, Ion , and Ion Carbonitriding. Implantation [To modify the bulk CRACK REDUCTION TECHNIQUES: properties.] Austempering, Martempering / Marquenching

DUCTILITY, TOUGHNESS, and MACHINABILITY changing processes: Annealing (Full and Process type), Normalizing, Tempering, Spheroidizing. STRENGTHENING processes: Solid Solution Strengthening, Grain Size Refinement, Strain Hardening, Precipitation or Age Hardening, Dispersion Hardening, and PhaseTransformation Hardening Intro to AMP by Dr. Sunil Pathak [1] CLASSIFICATION OF VARIOUS MANUFACTURING (Continued)

Advanced Basic or Traditional or Conventional Processes Unconven Nature tional Processes For burr Removal: BURR REOMVAL: Grinding, Chamfering, Filing, Centrifugal and Spindle Finishing, Thermal- USM, AJM, WJM, energy Deburring, Power Sanding, Power Brushing, and Mechanical Cleaning Processes as AWJM, AFM, CHM, described below. ECDE MECHANICAL CLEANING and FINISHING: Abrasive Finishing And Cleaning, Barrel Finishing Or Tumbling, Vibratory Finishing, Belt Sanding, Wire Brushing, Buffing, Surface Electro-polishing. Treatment CHEMICAL CLEANING: Vapor Degreasing, Acid Pickling, Alkaline, Solvent, And Processes Ultrasonic Cleaning.

[To modify the COATING (Liquid/Gas Deposition): Painting, Chemical Conversion surface COATING Coating, Hot Dip Coating, Electro-plating, Anodizing, Electroless or properties.] TECHNIQUES Autocatalytic Plating, Mechanical Plating, Porcelain Enameling. CLADDING (Solid deposition) VAPORIZED Physical Vapor Deposition (PVD): METAL Vacuum Metallizing, Sputtering, Ion Plating COATING Chemical Vapor Deposition (CVD) Intro to AMP by Dr. Sunil Pathak Courtesy: Prof. N K Jain (IIT Indore, India) Types of AMPs

 Basic AMPs: 15 (8 Mechanical + 1 Electrochemical + 1 Chemical + 5 Thermal)

 Derived AMP: Modification of Basic AMP to Meet SpecificObjectives Electro Stream Drilling (ESD) Derived AMPs from ECM Shaped Tube Electro Machining (STEM) Electrolytic Jet Drilling (EJD) Derived AMP from CHM Photo Chemical Machining (PCM) Derived AMP from EDM Wire Electro Discharge Machining (WEDM) Derived AMP fromAFM Centrifugal Force Assisted Abrasive Flow Machining(CFA-AFM)

Derived Version of HMP have also ReportedTW-ECSM

 Hybrid Machining Processes (HMPs)

Intro to AMP by Dr. Sunil Pathak Courtesy: Prof. N K Jain (IIT Indore, India) Hybrid Machining Processes (HMPs) [1] Concept of HMP Combining Either Two or More than Two AMPs or AMP + Conventional Machining Process

[2] When to Conceptualize and Develop an HMP ?

 To Simultaneously Exploit the Potentials and Capabilities of the Constituent Processes; and / or

 To Minimize the Adverse Effects Induced When a Constituent Process is Used Independently

 Generally, Development of an HMP is either Material or Shape

Application Specific Intro to AMP by Dr. Sunil Pathak Courtesy: Prof. N K Jain (IIT Indore, India) HMPs are Gaining Considerable Attraction  Meet Some of the Ultraprecision Machining Requirements  Meet High Productivity Requirements for the Components Made of Advanced DTM Materials  Meet the Challenging Stringent Design Requirements  Meet Extreme Surface Quality and Tolerance Requirement Types of HMPs [Can be Classified Into Two Major Categories (Kozak & Rajurkar, 2001)]  Processes in which Constituent Processes are Directly Involved in Material Removal;  Processes in which only ONE of the Participating Processes Directly Removes the Material while others Only ASSIST in Removal By Changing the Conditions of Machining in a Positive Manner  Most of the HMPs are in their Inception and Development Phase  Sustained Research is Required to Transform HMPs into a Matured Manufacturing Technology and forTheir Successful Commercialization and Industrial Applications Intro to AMP by Dr. Sunil Pathak Process Combining Mechanism of Tool Transfer Energy Sources Material Removal Media Conventional Machining + ElectrochemicalAMP ECH Electrochemical + Electrochemical Dissolution Abrasive Sticks Electrolyte Mechanical andAbrasion ECG Electrochemical + Electrochemical Dissolution AbrasiveWheel Electrolyte Mechanical andAbrasion ECAG Electrochemical + Electrochemical Dissolution Metal Bonded Electrolyte Mechanical andAbrasion AbrasiveWheel Conventional Machining + ThermalAMP Examples of AEDM Mechanical + Melting, Evaporation and LooseAbrasive Dielectric Thermal Abrasion Particles HMPs EDAG Mechanical + Melting, Evaporation and Metal Bonded Dielectric Thermal Abrasion AbrasiveWheel [Conventional EDDG Mechanical + Melting, Evaporation and Diamond wheel Dielectric Thermal Abrasion Machining + LAT Mechanical + Shearing and Heating TurningTool Air Thermal AMP] PAT Mechanical + Shearing and Heating TurningTool Air Thermal LAE Chemical + Chemical Dissolution and Mask Etchant Thermal Heating Conventional Machining + MechanicalAMP RUM Mechanical + Abrasion Sonotrode having Coolant Ultrasonic Vibration DiamondAbrasives UAT Mechanical + Shearing TurningTool Air Intro to AMP by Dr. Sunil Pathak Ultrasonic Vibration Process Combining Mechanism of Tool Transfer Energy Sources Material Removal Media Electrochemical +Thermal ECSM or Electrochemical + Melting and/Or Electrode Electrolyte Thermal Evaporation ECAM

LAECM Electrochemical + Electrochemical Electrode Electrolyte Thermal Dissolution and Heating Electrochemical + Mechanical USECM Electrochemical + Electrochemical Sonotrode Electrolyte Ultrasonic Vibration Dissolution Examples of ECMAF Electrochemical + Electrochemical Abrasives Electrolyte Mechanical Dissolution +Abrasion HMPs [Two or Mechanical +Thermal MoreAMPs] USEDM Thermal + Melting and Evaporation Sonotrode Dielectric Ultrasonic Vibration USLBM Thermal + Melting and Evaporation Laser Beam Air Ultrasonic Vibration Two MechanicalAMPs MRAFF Two MechanicalAMPs Shearing Abrasives MR Fluid More than TwoAMPs BEDMM Electrochemical + Electrochemical, Melting Rotating Metal Water Glass Mechanical + and Mechanical Rupture Brush Solution In Thermal Water Intro to AMP by Dr. Sunil Pathak Typical Examples of Parts Developed by AMPs

MALE

FEMALE

PRECISION WIRE EDM

Design Made using 3D Printing Figure:1 Typical parts made by electrochemical machining. (a) Turbine blade made of nickel alloy of 360 HB. Note the shape of the electrode on the right. (b) Thin slots on a 4340-steel roller-bearing cage. (c) Integral airfoils on a compressor disk. Intro to AMP by Dr. Sunil Pathak Important Characteristics Process performance is independent of Workpiece Material properties such as of AMPs hardness.Toughness, ductility, brittleness etc.

Process Performance highly depends upon the thermal, electrical, magnetic and chemical properties of the workpiece material

Process utilizes Usually AMPs Possesses lower material removal different types of rate as compared to conventional processes but source energy i.e. in turns AMPs provide high quality parts Mechanical, Thermal, Electrical and Initial investment cost of setting an AMP is high due to costly Chemical in its direct machine tools and high operating costs form

Intro to AMP by Dr. Sunil Pathak Dr Sunil Pathak, PhD - IIT Indore (MP) India Senior Lecturer Faculty of Engineering Technology University Malaysia Pahang, Kuantan Malaysia https://www.researchgate.net/profile/Sunil_Pathak4 https://scholar.google.co.in/citations?user=9i_j3sMAAAAJ&hl=en

Intro to AMP by Dr. Sunil Pathak