Introduction

to
Advanced Manufacturing Processes

Dr. Vijay Mandal

Assistant Professor
Department of Mechanical Engineering
NIT Mizoram
 Advanced Manufacturing Processes

Advanced Manufacturing Processes" refer to innovative

technologies and methods used in the production of goods,
which go beyond traditional manufacturing techniques. These
processes often incorporate cutting-edge tools, materials, and
techniques to improve efficiency, precision, sustainability, and
overall product quality.
 PRESENT DAY DEMAND TRENDS IN INDUSTRIES
(AEROSPACE , MISSILES , AUTOMOBILES, NUCLEAR REACTORS, ETC.)

ENGG. MATERIALS HAVING MUCH ULTRA HIGH STRENGTH , HARDNESS

SUPERIOR VERY HIGH TEMPTURE RESISTANCE
PROPERTIES DIFFICULT TO MACHINE BY
CONVENVENTIONAL MACHINING
METHODS

WORK PIECE MATERIAL HARDNESS >> TOOL MATERIAL HARDNESS

HOW TO SOLVE THE PROBLEM ?

ADVANCED MACHINING PROCESSES
WORKPIECE HARDNESS DOES NOT MATTER IN AMPs
Overall, Limitations of Conventional Machining Methods

► Increased workpiece hardness : decreased economic cutting

speed. Hence, lower productivity.
► Rapid improvements in the properties of materials
(hardness, strength, etc)
► Requires much superior quality of tool materials.
► Tool material hardness should be greater than workpiece
hardness.
Evolution of Advanced Machining Processes(AMPs)

► Many Engineering materials are having much superior

properties such as ultra high strength , hardness, very high
temperature resistance difficult to machine by convenventional
machining methods.
Ex :Tungsten Carbide, Stainless Steel, Titanium and its alloys
etc
► If work piece material hardness is greater than the tool
material hardness. How are we going to machine such a work
piece material ?
 ▪ CLASSIFICATION BASED ON THE KIND OF ENERGY USED : MACHANICAL,
THERMOELECTRIC, ELECTROCHEMICAL & CHEMICAL, BIOCHEMICAL

ELECTROCHEMICAL &
MECHANICAL THERMOELECTRIC
CHEMICAL

MACHINING
PLASMA ARC MACHINING (PAM) ELECTROCHEMICAL MACHINING
ABRASIVE JET MACHINING (AJM)
(ECM)

ULTRASONIC MACHINING (USM) LASER BEAM MACHINING (LBM) CHEMICAL MACHINING (CHM)

WATER JET MACHINING ELECTRON BEAM

BIOCHEMICAL MACHINING (BM)
(WJM) MACHINING (EBM )

ABRASIVE WATER JET MACHINING ELECTRIC DISCHARRGE MACHINING (

(A WJM) EDM)

FINISHING
ABRASIVE FLOW FINISHING (AFM) ION BEAM MACHINING(IBM)

MAGNETIC ABRASIVE FINISHING

(MAF)

MAGNETORHEOLOGICAL
FINISHING (MRF)
14
Classification of AMPs, Based on Properties of work
material

► Applicable only for Electrically Conducting Materials : ECM,

EDM, EBM.
► Applicable for both electrically conducting & non - conducting
materials: USM, AJM, LBM, etc.
► Applicable for Non Magnetic materials : MAF, MRF, etc.
► Thermal conductivity, Reflectivity, etc. also play an important
role in some processes: LBM
Advanced Manufacturing Processes

Dr. Vijay Mandal

Assistant Professor
Department of Mechanical Engineering
NIT Mizoram
 ▪ CLASSIFICATION BASED ON THE KIND OF ENERGY USED : MACHANICAL,
THERMOELECTRIC, ELECTROCHEMICAL & CHEMICAL, BIOCHEMICAL

ELECTROCHEMICAL &
MECHANICAL THERMOELECTRIC
CHEMICAL

MACHINING
PLASMA ARC MACHINING (PAM) ELECTROCHEMICAL MACHINING
ABRASIVE JET MACHINING (AJM)
(ECM)

WATER JET MACHINING LASER BEAM MACHINING (LBM) CHEMICAL MACHINING (CHM)
(WJM)

ELECTRON BEAM
ULTRASONIC MACHINING (USM) BIOCHEMICAL MACHINING (BM)
MACHINING (EBM )

ABRASIVE WATER JET MACHINING ELECTRIC DISCHARRGE MACHINING (

(A WJM) EDM)

FINISHING
ABRASIVE FLOW FINISHING (AFM) ION BEAM MACHINING(IBM)

MAGNETIC ABRASIVE FINISHING

(MAF)

MAGNETORHEOLOGICAL
FINISHING (MRF)
14
Outlin
e

• Abrasive Jet Machining

• Water Jet Machining

• Abrasive Water Jet

• Ultrasonic Machining
Introduction to Abrasive Jet Machining (AJM)

• In AJM, the material removal takes place due to impingement

of the fine abrasive particles.
• The abrasive particles are typically of 0.025mm diameter and
the air discharges at a pressure of several atmosphere.
Mechanics of AJM

Abrasive particle impinges on the work surface at a high velocity

and this impact causes a tiny brittle fracture and the following
air or gas carries away the dislodged small work piece particle.
AJM System
Abrasive Jet Machining: Machined products
AJM Process Parameters
contd.
► Carrier Gas:

Composition ρ(kg/m3) V (m/s) P(bars)

Carrier Gas Air,CO2,N2 1.3 500 −700 2 −10
► Abrasive Jet:

SOD(mm) Impinge V (m/s) Mixing ratio

Abrasive Jet 0.5-15 60 −90◦ 100 −300 V˙abr /V˙gas
► Nozzle:

Material Diameter(mm) Life(hrs) NTD(mm)

Nozzle WC,Sapphire 0.2-0.8 12-300 0.25-75

► Note: SOD-Stand of Distance, NTD: Nozzle to Tip Distance

Parametric Analysis in AJM

► Effect of Nozzle Tip Distance (NTD) on cavity diameter

► Effect of Nozzle Tip Distance (NTD) on MRR

Parametric Analysis in AJM

► The NTD not only affects the MRR from the work surface but
also the shape and size of the cavity produced.
► when the NTD increases, the velocity of the abrasive particles
impinging on the work surface increases due to their
acceleration after they leave the nozzle. This increases the
MRR. With a further increase in the NTD, the velocity
reduces due to the drag of the atmosphere which initially
checks the increase in MRR and then decreases it.
► Effect of Abrasive flow rate on MRR

Parametric Analysis in AJM

► As the flow rate increases upto maxima, More number of

abrasive particles hit the surface. this increases the MRR.
► If flow rate is greater than the optimum, velocity of the jet
decreases hence MRR also decreases.
► Effect of Mixing Ratio on MRR

Parametric Analysis in AJM

► Note: Mixing Ratio(m) is the ratio of volume flow rate of

abrasive to the volume flow rate of carrier gas. (α=mass
ratio) α is the ratio of mass flow rate of abrasive to the mass
flow rate of abrasive and gas carrier
˙
m= V a α= ṁa
(20)
V˙g ṁa+g
Water Jet
Machining

► It has multidirectional cutting capacity with no heat produced.

► Cuts can be started at any location without the need for
predrilled holes.
► The burr produced is minimal.
► Grinding and polishing are eliminated, reducing secondary
operation costs.
Water Jet Machining-Products
Abrasive Water Jet
Machining

► Cut virtually any material.

► Cut thin or thick stuff and No heat generated.
► Abrasive Water jet cutting can be easily used to produce
prototype parts very efficiently.
Different engineering components machined with AWJM
 Ultrasonic Machining (USM)

The use of Ultrasonics in Machine was first proposed by J.O. Farrer in 1945.
The first machine tool using ultrasonic principle was designed in 1954.
Originally, USM used to be for finishing operations on components produced by
electro-spark machining.
This use became less important because of the development in electric
discharge machining.
Ultrasonic machining also gained prominence in machining electrically
nonconducting, semiconducting and brittle materials in the expanding
electronic industry.
 Basics of the USM process
The basic USM process involves a tool ( made of a ductile and tough material) vibrating with a
very high frequency and a continuous flow of an abrasive slurry in the small gap between the
tool and the work piece.
The tool is gradually fed with a uniform force.
The impact of the hard abrasive grains fractures the hard and brittle work surface, resulting in
the removal of the work material in the form of small wear particles.
The tool material being tough and ductile wears out at a much slower rate.
Ultrasonic Machining (USM) Animation
 MRR (Q)

𝑑𝐹 3/4 𝐴3/4 𝐶 1/4

Q∝ 3
ൗ 3
𝑣
𝐻𝑤 4 (1+𝜆) ൗ4
Plot between MRR and Feed force

MRR increases
with increasing
feed force but
after a certain
critical feed force
it decreases.
 Process Parameters
We already said that with an increase in static loading, the mrr tends to increase.
However, at higher force values of the tool head due to grain crushing the mrr
decreases.

The ratio of workpiece hardness and tool hardness affects the mrr quite
significantly, and the characteristics is shown below.

Apart from the hardness the brittleness of the work material plays a very dominant
role. The table below shows the relative mrr for different work materials. As can be
seen the more brittle material is machined more rapidly.
 Laser Beam Machining

Dr. Vijay Mandal

Assistant Professor
Department of Mechanical Engineering
NIT Mizoram
Electromagnetic Radiation
Electric Field
Magnetic Field

Wavelength (m)

Shorter wavelength = More energy

In an electromagnetic wave, the electric field (E) and magnetic field (B) are always
perpendicular to each other and to the direction in which the wave is traveling.

The speed at which electromagnetic waves propagate in a vacuum is the speed of light
(c), approximately 3×108 m/s.
 Light Amplification by
Stimulated Emission
of Radiation

▪ The underlying concept of laser operation, was first introduced by Einstein

in 1917 in one of his three papers on the quantum theory of radiation
(Einstein 1917).

▪ In 1960, T.H. Maiman came up with the first working ruby laser. The three
processes required to produce the high energy laser beam are population
inversion, stimulated emission, and amplification.
 Introduction

► A laser is a device that emits light through a process of optical

amplification based on the stimulated emission of electromagnetic
radiation. The term ”laser” originated as an acronym for:
Light Amplification by Stimulated Emission of Radiation
► Lasing process describes the basic operation of laser, i.e.
generation of coherent (both temporal and spatial) beam of light
by ”light amplification” using ”stimulated emission”.
► The laser differs from other incoherent light because it is:
1) Monochromatic
2) Coherent
3) Directional or collimated
4) Bright
-
Principle of LASER

► The electrons at ground state can be excited to higher state

of energy by absorbing energy form external sources like
electronic vibration at elevated temperature, through chemical
reaction or by absorbing photons.
► On reaching the higher energy level, the electron reaches an
unstable energy band. And it comes back to its ground state
within a very small time by releasing a photon. This is called
spontaneous emission.
Spontaneous vs. Stimulated Emission
E2
• More electrons at any
given temperature occupy
lower energy state

E1
• External excitation would
transfer the electrons in
E2 the medium from lower
Ephoton energy state to higher
= energy state(s)
E2- E1

• Electrons will return to

E1 ground state emitting
photons of energy
E2 difference

• Simultaneous excitation
Ephot
de-excitaion leads to
on simulated emission
E1
Laser Material Interaction
 Laser Micro Drilling/ablation 3
9

Laser ablation Cold Ablation

(Source: www.astrobio.net/pressrelease/ Melt- Vaporization
4605/green-laser-spectroscopy)

Array of <10 μm
hole on Thin gold
LASER applications
 Electron Beam Machining

• Electron beam machining is a thermal process where a stream of electrons

of high speed impinges on the work surface whereby, the kinetic energy
transferred to the work material , produces intense heating.
• Depending on the intensity of the heat thus generated, the material can melt
or vaporize.
• The process of heating by an electron beam can, depending on the intensity,
be used for annealing, welding, or metal removal.
• Very high velocities can be obtained by using enough voltage, for example,
an accelerating voltage of 150,000V can produce an electron velocity of
228,478 km/ sec.
• Since an electron beam can be focused to a point with 10-200 μm diameter,
the power density can go up to 6500 billion W/mm2 .
• Such a power density can vaporize any substance immediately.
• Thus, EBM is nothing but a precisely controlled vaporization process.
 Schematic view of the e-beam machine
• The figure below shows the basic schematic view of the electron beam machine.
• The electrons are emitted from the cathode (a hot tungsten filament), the beam is shaped by
the grid cup, and the electrons are accelerated due to a large potential difference between the
cathode and the anode.
• The beam is focussed with the help of the electromagnetic lenses.
• The deflecting coils are used to control the beam movement in any required manner.
• In case of drilling holes the hole diameter depends on the beam diameter and the energy
density.

• When the diameter of the

required hole is larger than
the beam diameter, the beam
is deflected in a circular path
with proper radius.
• Most holes drilled with e-
beam are characterized by a
small crater on the beam
incident side of the work.
 Mechanics of EBM process
• Electrons are the smallest stable
elementary particles with a mass
of 9.109X10-31 Kg and a negative
charge of 1.602X10-19 C.

• When an electron is accelerated

through a potential difference of V
volts, the change is Kinetic
energy can be expressed as ½
(me )(u2-u02 ) eV, where me is the
electron mass. u, is the final
velocity, u0 is the initial velocity,
and e is the electron charge.
• If we assume initial velocity of the emitting electron to be negligible, the
final expression for electron velocity u in km/sec. is given by:

u = 600 (V)1/2
where, V is the potential difference
• When a fast moving electron impinges on a material surface, it penetrates
through a layer undisturbed.
• Then it starts colliding with the molecules, and ultimately, is brought to rest.
Electrochemical Machining (ECM)
Dr. Vijay Mandal
Assistant Professor
Department of Mechanical Engineering
National Institute of Technology Mizoram
Why Electrochemical Machining

Features with tight dimensional tolerance can be machined

using Electrochemical Machining (ECM) / Electrochemical
Micromachining (ECMM) and therefore, the process has
emerged as an ideal option for micromachining.

Roughness of the surface machined using ECM is generally

less than that of jet machining processes. This makes ECM
and its variants as the most suitable option for operations
requiring high surface finish.

Power required for removing a unit volume of material per

unit time in ECM is less than that of EBM, AJM, LBM,
AWJM, and WJM. This suggests that machining using ECM
process offers economic advantage.

Although EDM is more conservative in power consumption,

but requires frequent tool change (due to rapid tool wear)
which also adds in its total machining cost. Fig 1. Comparison between different machining
processes in terms of machining tolerance, generated
surface roughness and specific power consumption
[1].
Fundamentals of anodic dissolution in ECM

During electrolysis, positive metal ions leave the

workpiece and electrons leave the tool to reach their
respective opposite ends. Reactions taking place at
anode and cathode are shown :

Anode: 𝑀 → 𝑀𝑛+ + 𝑛𝑒 −
𝑛
Cathode: 𝑛𝐻 + + 𝑛𝑒 − → 𝐻2
2
where, n is the number of valence electrons.

The anodic reaction leads to the formation of metal anions

compounds (heavier than other ions) and losing H+ ions
(which reduces the electrolyte conductivity) but cathodic
reaction leads to electron interaction. Fig. 2. Schematic diagram showing the movement of electrons
and ionic species during electrolysis and dissolution of anode
Hydrolysis of water generates H + and OH- ions. As material [1].
machining progress, the conductivity continues to decrease Material removal rate i.e. (MRR) is given by:
and pH increases. In practice, metal hydroxide and metal 𝐴𝐼
𝑀𝑅𝑅 =
chloride would form and get precipitated as sludge when 𝜌𝑍𝐹
aqueous NaCl is used as an electrolyte for machining steel. where, I is current flowing through the circuit, F is faraday’s
constant(96500 C), A= atomic mass of the substance and Z is
valence number of ions of the substance
Fundamentals of anodic dissolution in
ECMthe electric potential is applied across the anode and cathode, the quantitative
When
relationship between the material removed and the charge passed is given by
faraday’s laws of electrolysis. The mathematical expression is given as:

𝑄 𝐴
𝑚= grams.*
𝐹 𝑍

Where, Q is the total electric charge passed through the substance, F is faraday’s
constant (96500 C), A= atomic mass of the substance and Z is valence number of ions of
the substance
Different components of ECM machine

Image source: Bijoy Bhattacharyya, Electrochemical Micromachining for Nanofabrication, MEMS and Nanotechnology
Applications of Electrochemical Machining (ECM)-Micro domain

Biomedic Micro
al fluidics
Markings
and
Aesthetics

Image source:
micropat.ch
Electrical Discharge Machining (EDM)

Dr. Vijay Mandal

Assistant Professor
Department of Mechanical Engineering
NIT Mizoram
 Electrical Discharge Machining (EDM):Introduction
1. An electro-thermal technique of material removal falls under the unconventional/non-traditional/advanced
machining category.

2. Most suitable for the processing of difficult-to-cut, exotic and ultra-hard materials especially used in various
industries viz. Aerospace, Nuclear, Automobile and Electronics industries.

3. Apparently, melting and subsequent evaporation are considered to be the principle of material removal in
this process, though the exact phenomenon governing material removal in the EDM process is still debatable.

4. Series of discrete discharges occurring between two electrically conductive electrodes submerged in an
insulating fluid, called Dielectric (generally liquid, gas or mist), resulting in heating and subsequent melting
and vaporization of the parent material.

5. Generation of spark requires a minimum gap between the two electrodes (tool and workpiece), owing to the
minimum electrical resistance/ highest electrical field at this point.
 Introduction to EDM process

Polarities in EDM

Advantages
Superior dimensional accuracy,
ability to create complex micro-features,
IEG: Inter-electrode gap, spark no direct contact,
gap/discharge gap, the gap between tool and machinability independent of the
workpiece.
hardness
 Fundamental insights into plasma material interaction

1. Application of open circuit voltage

across the electrodes.
2. Cold emission of electrons from the
cathode.
3. Due to the ionization of dielectric
atoms/molecules, the formation of
the plasma channel.
4. Current flows through the plasma
channel, resulting in Joule heating.
5. A fraction of energy is shared with
the workpiece and tool.
6. Melting and vaporization of the
electrodes.
7. Pulse-off time: Plasma collapsing
phase, removes molten material and
debris.
8. Dielectric reionization for next Plasma formation mechanism and crater evolution in the EDM
pulse/discharge. process.
 EDM: Applications

Usin
g
WE
DG
Stepped
tool

μED-Milling for turbine impeller and finished

component after machining. Liu et al.
In-situ micro-tool fabrication. Long et
Array of micro-holes. Long et al.
al.

Micro-slot machining. Asad et al. High aspect-ratio cooling holes for

Hole of 6.5 μm diameter. Asad et turbine blade.
al.