Advanced manufacturing processes (ME F315

Department of Mechanical
Engineering
BITS Pilani K. K. Birla Goa campus
Instructor in charge: Dr. Biswajit Das
Office No.- E107
Tel: +91-832-2580381 (O)

Dr. Manoj Kumar Pandey

BITS Pilani K. K. Birla Goa campus
ECM
WJM
CHM
Fabrication of large size domes

Fabrication of Micro-lens
Conventional Machining Processes (Material Removal):
Primarily rely on electrical motors and hard tool materials
to perform tasks e.g. Turning, Drilling, Boring, Milling,
Shaping, Sawing, Slotting, & Grinding etc.

Main Characteristics of Conventional Machining:

* Material removal by chip formation
* Material removal by mechanical force
* Cutting tool – harder than work piece under machining condition
* Direct mechanical contact - residual mechanical & thermal stress.
Need of Modern Manufacturing Processes !
Challenges & Competition in manufacturing industries:
New Products - Better Performance, More Features, More Durable, Less Production
Time, Energy Efficient, Low cost,
Demand for Products with
 New exotic work materials: Improved mechanical, thermal, & chemical
properties
Super alloys, ceramics and composites
* Too hard / brittle to machine with traditional process
* Materials too flexible / slender to cut or clamp
Ex: Machining Polycrystalline diamond
- fast wear of grinding wheel; Quartz
Silicon wafer, Ceramic – Damage during machining
 Innovative designs, complex shapes, high precision & high surface quality
* Stringent design requirements * Micro- Nano Sizes

Micro-lenses

60m square hole in Si Curved slot in SS

 Other requirements of the New Manufacturing Process

 Low machining cost

* Automated processing, Fast production
 Rapid change of Product design
* Elimination of Traditional tooling to reduce time & cost

 Less Temperature rise or residual stresses

Photochemical Machining Electro-Discharge Machining

 Modern / Nontraditional Manufacturing processes employing
New tools and
New forms of energy
Developed as
Efficient and economic alternatives to conventional ones

Often the first choice for certain technical requirements.

Modern / Nontraditional Manufacturing Processes differ to Traditional Mfg.

Processes in following aspects 

 Unconventional Energy Sources : Thermal, Chemical, Kinetic Energy ----

 Processing usually not by direct MECHANICAL contact: Nontraditional
mechanism of interaction between the tool and the work piece: Evaporation,
Ablation, Melt Ejection, Dissolution, Erosion----
 Nontraditional media to transfer energy from the tool to the work piece :
Photons, E-beam, Dielectric media, Electrolytic media, Water, Abrasive slurry.
Classification of NTM Processes

* Thermal NTM Processes

- Laser Beam Machining (LBM)
- Electron Beam Machining (EBM)
- Plasma Arc Machining (PAC)
- Electrical Discharge Machining (EDM)
* Mechanical NTM Processes( Plastic deformation / Abrasive Erosion)
- Abrasive Jet Machining (AJM)
- Ultrasonic Machining (USM)
- Water Jet Machining (WJM)
- Abrasive Water Jet Machining (AWJM)
* Electrochemical NTM Processes
- Electrochemical Machining (ECM)
- Electrochemical Grinding (ECG)
* Chemical NTM Processes
- Chemical Machining (CHM)
- Thermo chemical Machining (TCM)
* Kinetic Energy ( Atom by atom knocking)
- Ion beam
Examples where NTM processes is the first choice

 Intricate shaped blind holes- e.g. square holes of say 10x10mm with a depth of
20mm  EDM / ECM

 Machining hard materials- e.g. Diamond, Inconel, Ti-Alloys, Composites,

Ceramics or Carbides  EDM, ECM, LBM

 Small diameter holes with large aspect ratio (0.5mm , 10mm l)

LBM, EBM, EDM
 Flexible , Brittle materials  WJ, AWJ, EDM, PCM, LBM, EBM

Abrasive Machining

Laser Cutting
Characteristics of Modern / Non Traditional Machining (NTM) Processes

 Mostly NTM processes do not use mechanical energy for material removal.
They use different forms of energy for machining.
Example, USM, AJM, WJM - Mechanical energy
ECM- Electrochemical dissolution
Laser, EDM, EB - Thermal

 Material removal with chip formation or even without chip formation

Example: AJM - Microscopic size chips
ECM - Electrochemical dissolution at atomic level

 In NTM, Physical tool may or may not be present.

Example: Laser beam machining- No tool,
Electrochemical Machining- Physical tool needed

 In NTM, Tool need not be harder than the work piece material.
Example, EDM, copper tool to machine hardened steels.

 Nontraditional media for energy transfer:

EDM: Dielectric fluid,
Laser: Coherent photon beam
 Attributes of Nontraditional Machining Processes

Increased Productivity: Faster operation

Reduction in the number of overall operations;

Reduced Rejection: Improved repeatability

Reduction in in-process breakage of fragile work piece.

Perform operation not feasible by traditional Manufacturing Processes,

Example drilling holes of very high depth to width aspect ratio, 100:1

Easy automation, On-line Process Monitoring & Control: Increased reliability,

repeatability; reduced human involvement

Versatile & Virtually unlimited Capability: Ex.- Laser can cut most materials of
any hardness: diamond, metals, concrete, glass, plastics, textiles, wood etc.
Drill holes of any diameter
Modern Manufacturing Processes
1. Laser Beam Machining ((Processing) (LBM)
2. Electron Beam Machining (EBM)
3. Plasma Arc Machining (PAC)
4. Ion Beam Machining (IBM)
5. Physical Vapour Deposition (PVD)
6. Chemical Vapour Deposition (CVD)
7. Abrasive Jet Machining (AJM)
8. Water Jet Machining (WJM)
9. Abrasive Water Jet Machining (AWJM)
10. Ultrasonic Machining (USM)
11. Electro- Discharge Machining (EDM)
12. Electrochemical Machining (ECM)
13. Chemical Machining (CHM)
14. Hybrid & Other Advanced Manufacturing Processes
Hybrid manufacturing processes
Comparison - Parameters
Comparison - Shapes

Through cavities Through cutting

Comparison - Shapes
Comparison - Materials

Tungsten,
Molybdenum,
Niobium, Tantalum
and Rhenium
Comparison – Capability & Cost

CLA = Center Line average

 Advantages of NTMT

 Complex geometries
 Extreme surface finish
 Tight tolerances
 Delicate components and features
 Easy adaptability for automation
 Little or no burring or residual stresses
 Easy to machine brittle materials with high hardness
 Mass production possible for micro electronics & Integrated circuits
 Intricate machining
Abrasive Jet Machining (AJM)
 AJM
• Material removal takes place due to the impingement of the fine abrasive
particles.
• Particles moves with high speed air (or gas) steam.
• The kinetic energy of the abrasive particles is sufficient to provide material
removal due to brittle fracture of the workpiece or even micro-cutting by
the abrasives.
• AJM is inherently free from chatter and vibration problems. The cutting
action is cool because the carrier gas serves as a coolant.

• AJM is mainly used

• To cut intricate shapes in hard and brittle
materials which are sensitive to heat and
chip easily.
• For deburring and cleaning operations.
Mechanics of AJM

Gas supply pressure is on

the order of 850 kPa
(~8bar)

Stages
 Equipment

Major Parameters which controls MRR, geometry of cut, SF and Nozzle wear
are
• Abrasive (composition, strength, size and mass flow rate)
• Gas (composition, pressure and velocity)
• Nozzle (geometry, material, distance from and inclination to the work
surface)
 Process parameters
• Abrasive
• Aluminium oxide (Al2O3) silicon carbide (SiC) glass beads,
crushed glass and sodium bicarbonate.
• Should have sharp edges
• Reuse is not recommended
 Process parameters

• Abrasive

Mixing ratio: Mass fraction of the abrasives in the jet.

 Process parameters

• Nozzle: Shapes
 Process parameters

• Nozzle: Effect of nozzle tip distance on shape and size of cut.

 Process parameters

• Nozzle: Effect of nozzle tip distance on shape and size of cut.

AJM Characteristics
 Advantages and Disadvantages

Advantages:
• There is no direct contact between the tool and the workpiece
(Ability to cut fragile materials).
• Good surface finish can be obtained.
• No heat damage to the workpiece (Ability to cut heat-sensitive
material).
• Hard materials can be easily machined.
• Complex shapes can be produced on the workpiece.
• Low initial cost.

Disadvantages:
• The material removal rate is low.
• Poor machining accuracy.
• High nozzle wear rate.
• The soft material cannot be machined.
• Additional cleaning of the work surface is required due to
the sticking of abrasive grains in softer material.
 Applications

• Cutting slots and thin sections.

• Contouring and drilling operation.
• Producing shallow crevices and deburring.
• Producing intricate hole shapes in a hard and brittle material.
• Machining of semiconductor materials.
• Cleaning and polishing the plastic, nylon and Teflon component.
• Frosting of the interior surface of glass tubes.
• Etching of marking of glass cylinders.
• Machining super-alloys and refractory material.
 Mechanics

Assumptions:
1. Abrasives are spherical in shape and rigid.
2. Kinetic energy of particle is used to cut the material.
3. For brittle Materials, fracture of volume is considered to be
hemispherical with diameter equal to chordal length of indentation.
4. For ductile material, volume of material removal is assumed to be
equal to the indentation volume due to particulate impact.
 Mechanics

From the geometry,

Thank you
for
your patience

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