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 machining – 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 Casting 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 Die Casting, Squeeze For Fabrication of Polymers: Thermoforming, Casting, Extrusion, 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 Metallurgy 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 Forming Processes Advanced Metal Forming Processes Processes Hot- Cold-working Processes High Energy Rate Forming (HERF) working Processes: [Formative: Rolling, Squeezing: Cold Rolling, Cold Forging , Electromagnetic Forming, Explosive Shapes The Forging, Cold Extrusion, Swaging, Sizing, Riveting, Forming, and Electro-hydraulic Material In Staking, Coining, Peening, Burnishing, Extrusion, Forming. Laser Bending, Solid State Hubbing, and Thread Rolling. Using Property Hot- Bending: Angle Bending, Roll Bending, 3d-laser Forming, drawing, Of Draw and Compression Bending, Roll- Hot Isostatic Pressing (HIP) Plasticity.] Piercing forming, Seaming, Flanging, and Straightening. For Sheet Metal 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/ Welding Consolidation - ary or semi- state Welding Liquid Techniques: Or permanent welding Electrical Chemical state EBW, Fabrication LBW, Thread Rivets, Friction, Arc welding: Gas Brazing, Processes USW joints Stitches, Forge, Using Consumable welding: Soldering, 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 Plating, 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.