Different Generations of Manufacturing Processes: a Critical Review
Total Page:16
File Type:pdf, Size:1020Kb
International Journal of Mechanical Engineering and Technology (IJMET) Volume 7, Issue 5, September–October 2016, pp.250–271, Article ID: IJMET_07_05_026 Available online at http://iaeme.com/Home/issue/IJMET?Volume=7&Issue=5 Journal Impact Factor (2016): 9.2286 (Calculated by GISI) www.jifactor.com ISSN Print: 0976-6340 and ISSN Online: 0976-6359 © IAEME Publication DIFFERENT GENERATIONS OF MANUFACTURING PROCESSES: A CRITICAL REVIEW Akshay Sanghavi, Utsav Khan, Snehaditya Sen, Eashan Sikder and Dr.Sushanta Tripathy Kalinga Institute of Industrial Technology, Bhubaneswar, Odisha, India ABSTRACT This paper attempts to form a chronological record of the various manufacturing processes from their period of origin to their modern iterations, including the various stages of evolution undergone by these.This attempt has been made in order to highlight the particular necessities which led to upgrading of each process from its former iteration so as to provide a line of thought for modern inventors to exploit and come up with ideas to further optimize and modernise these manufacturing processes. This would help to break new grounds in the field of manufacturing and hence enable more efficient use of available resources and also obtain more precise and accurate products. Cite this Article: Akshay Sanghavi, Utsav Khan, Snehaditya Sen, Eashan Sikder and Dr. Sushanta Tripathy, Different Generations of Manufacturing Processes: A Critical Review. International Journal of Mechanical Engineering and Technology, 7(5), 2016, pp. 250–271. http://iaeme.com/Home/issue/IJMET?Volume=7&Issue=5 1. INTRODUCTION The subject matter of this paper is to present the development and change of Manufacturing Process in different generations.We shall represent various developments and innovations in the time distinguishing different possibilities of growth and research. The processes from the beginning have been divided into various sections and to be specific it is being cleaved into 8 generations with a decade making up a generation.In total 8 generations are illustrated from the origin of production and until the future. We have taken into consider the commonly used methods as the overheads and gave way to branching as the timeline proceeded and approached towards the modern methods.The noteworthy aspect in the content below, is the fact that the new methods have emerged as solutions to some problems faced with the preceding methods.Any succeeding method comes with some advantage in terms of resource utilisation and/or utility. Some of the methods have come to existence in order to achieve highly specific requirements and find less extensive use, however, these cannot be completely done away with.As new materials are being discovered or synthesised and new technologies are being implemented, the sphere of manufacturing processes is also changing its characteristics.Not only are the older root processes undergoing branching, but also some new root processes are coming into existence, which hardly bear much significance with the older processes.This only indicates that the possibilities of the future are endless and this fact is fairly motivating for the researchers in this field of study. http://iaeme.com/Home/journal/IJMET 250 [email protected] Different Generations of Manufacturing Processes: A Critical Review Generation 8 Generation 7 Generation 6 Generation 5 Generation 4 Generation 3 Generation 2 Generation 1 Figure 1 Schematic Illustration of different generations Generation 1 • Investment Casting • Rolling • ARC WELDING: • Composite material • Grist Mill - 71 BC • Sand Casting • Smith Forging 1881(PARIS) :1907 • Hammer Mill - 4th • Centrifugal Casting • Thermoforming • Shielded metal arc Century • Die Casting • Stamping welding (SMAW):Around • first boring machine 1900 • Continous Casting • Press Forging tool in 1775. • OXY-FUEL WELDING: • Power Metallurgy • Turning - 1850s 1903 • Drop Forging • Ball Mill - 1870s • LOW-FREQUENCY • true milling machine- ELECTRIC RESISTANCE 1912. WELDING: 1920s until • 1940, automation via 1970 cams • Submerged arc welding • Ultrasonic Machining - (SAW): IN 1935 1945 • Electroslag welding (ESW): February 1940 JOINING CASTING (patent 2191481) • Gas tungsten arc welding MACHINING (GTAW): 1941 • Gas metal arc welding (GMAW):In 1948 MOLDING AND FORMING MOLDING ADDITIVE MANUFACTURING ADDITIVE http://iaeme.com/Home/journal/IJMET 251 [email protected] Akshay Sanghavi, Utsav Khan, Snehaditya Sen, Eashan Sikder and Dr. Sushanta Tripathy Generations 2 and 3 • Full Mould Casting • Vaccum Forming - • Flux-cored arc • 1950s, servomechani and Lost Foam 1950 welding (FCAW): sms were applied to Casting - 1958. 1950s ) computerized • Spray Forming - numerical control • Rheo Casting - 1970. • Ultrasonic (CNC). 1971 • Hot isostatic Welding (USW): • 1952, numerical • Counter Gravity pressing (HIP)- 1965 control reached the Casting - 1972 1970s developmental stage of laboratory reality • Metal injection • electron System - 1970s beam processing • Rapid prototyping machine - 1952. • 1970s gas-assisted • Rotary ultrasonic injection molding machining was invented by Legge JOINING CASTING (1964). MACHINING • 1965, the first production laser cutting machine • 1967, laser-assisted oxygen jet cutting MOULDING AND FORMING MOULDING AND ADDITIVE MANUFACTURING ADDITIVE • NC evolved into CNC - 1970 Generations 4-8 • 1990 Aluminum • Friction Stir welding - • Selective Laser • Integrated plasma, a 1991 Sintering (SLS): mid- system that closely molds first used • Introduction of magnetic 1980s widely in injection coupled the CNC, the pulse welding. • Fused deposition plasma power moulding • Development of laser- modelling (FDM) : 1980 arc-hybrid welding • 3D PRINTING :1984 supply, the gas flow • Development of Gas • Stereolithography (SLA): control, the CAM Metal Arc Welding- 1986 software, and the Brazing, an process for • Cold spraying, involves height control welding steel used in blasting metallic system to automate autos. Process uses a particles through a the process. filler metal comprised of nozzle at such high silicon with a copper speeds that they bind to alloy. 2013 each other to form • Low-carbon steel and shapes. aluminum welding using • Digital manufacturing a lap joint and laser JOINING technologies. CASTING technology - 2013. • Advanced Water Removal via Membrane MACHINING Solvent-Extraction Technology. MOLDING AND FORMING MOLDING ADDITIVE MANUFACTURING ADDITIVE 2. LITERATURE REVIEW The research on the manufacturing process of the future has gained huge attention of the engineers and researchers in present times.This need and urgency has led to advancement in manufacturing production. 2. 1) Casting –Casting is the 6000 years old process and helps to produce various products complex in shape whose production would not have been viable with other process. http://iaeme.com/Home/journal/IJMET 252 [email protected] Different Generations of Manufacturing Processes: A Critical Review A. Investment Casting -Investment Casting is the oldest known metal forming process.It acquires its name from the refractory material investing the pattern.It produces products with excellent surface quality and low tolerances with minimum machining process required.The paper by S.Jones and C. Yuan on Investment Casting focuses on the advancement in shell moulding in the process.The Inference available is that with the improvement of Mechanical properties of the ceramic shell will lead to greater success in improving the performance.The other paper by Jean-Christophe Gebelin, Mark R Jolly describes the whole Investment Casting process modelling. Author(s) Focus Findings S. Jones and C. Yuan. The advancement in shell The paper explains the basic method (2nd December 2002) moulding for the applied for casting and its advantage in Investment casting. different sectors.Development of the Mechanical and Physical properties the ceramic shell will get us to the goal of improving shell performance. Jean-Christophe Gebelin, Investment casting The main finding from the paper is the Mark R Jolly. process modelling. understanding of the physical (20th Feb 2003) phenomenon controlling investment casting processes.The results are compared with the experimental data and then presented. Figure 2 Investment Casting (Source: http://moderninvestmentcast. com/wp-content/uploads/2015/09/investing-casting. png) B. Sand Casting - Sand casting is a good option, if you already have a part.And you can draw a parting line on the part so that the both halves can be pulled from the sand without distorting the sand.The paper by Jilin Li, Rongshi Chen, ,Yuequn Ma, Wei Ke analyses the Microporosity Defect in Sand Cast WE54 Alloy Castings.The experimental results obtained confirm the theoretically proved defects.The next one by Yuki Inouea, Yuichi Motoyamaa, Hiroki Takahashia, Keita Shinjia, MakotoYoshidab finds the restraints force by FEM analysis.The other paper points out the loads in casting and the effects of after casting. http://iaeme.com/Home/journal/IJMET 253 [email protected] Akshay Sanghavi, Utsav Khan, Snehaditya Sen, Eashan Sikder and Dr. Sushanta Tripathy Author(s) Focus Findings Jilin Li, Rongshi Chen, Characterization and The microstructure of the microporositydefects on Yuequn Ma, Wei Ke. Prediction of the WE54 alloysand casting wasobserved by (1st April 2014) MicroporosityDefect in Sand opticalmicroscopy and scanning Cast WE54 Alloy Castings. electronmicroscopy.By comparing the experimental and simulatingresults, itisfoundthat the predictedmicroporosityregions by Niyamacriterionagreeswellwithexperimentalresults.