Advanced Manufacturing Processes

Introduction
Dr. Harlal Singh Mali
Why need of Advanced Machining Methods/Processes
 Limitation of Conventional Machining Methods
 Rapid Improvements in The Properties of Materials
• Metals & Non-metals
• Tool Material Hardness
• Work piece Hardness
 Product Requirements
• Complex Shapes
• Machining In Inaccessible Areas
• Low Tolerances
• Better Surface Integrity
• High Surface Finish
 High Production Rate
 Low Cost of Production
 Precision & Ultra-precision Machining (Nanometer Machining)
 Requires Material Removal in form of Atoms or Molecules

Some Important Characteristics of AMPs

• Performance is Independent of Strength Barrier
• Performance Depends on Thermal, Electrical or Chemical Properties of W/P
• Uses Different kinds of Energy in Direct Form

Dr. Harlal S. Mali, MNIT Jaipur Page 1

 • In General, Low MRR But Better Quality Products
• Comparatively High Initial Investment Cost

Why AMP’s (Cont...)

• Material (super alloys) increases work-piece hardness.
• Work-Piece Complexities (3-D components).
• Miniaturisation.
• High Surface Quality (Ra in mm).
• Low Tolerances
• Conventional (single point or multi point cutting tool).
• Better surface integrity.(Poor Surface Finish leading to Fatiuge Cracks, µ-
cracks, HEZ)
• Advanced industries- aviation , space, nuclear and automobile.
• Newer material developed. E.G:- Plastics, ceramics and composites.
• Economy Demand.
• Miniaturisation.
• Complex geometries. E.G:- Hole making- shallow entry angle, non circular,
micro size, large aspect ratio, large no. of holes, holes without burr.

Why AMP’s For Advanced Material

• Ultra High Strength
• High Hardness
• High Temperature Resistance (Turbine blades 1200 ͦC to operate.
• Difficult to machine as conventional work-piece hardness << tool hardness.
• AMP tool hardness does not matter.

Dr. Harlal S. Mali, MNIT Jaipur Page 2

Other Names Of AMP’s
• Un-conventional
• Non traditional
• Precision/ ultra precision
• New Technologies

Advantages Of AMP’s
• Low cost of production (on Specific cases).
• Low chip size due to tight tolerances.
• Precision and ultra-precision machining.(material removal in the form of
atoms or molecules).

Classification Of Advanced Machining Processes

Mechanical Thermoelectric Electrochemical &

• Abrasive Jet Machining
• Ultrasonic Machining
• Water Jet Machining
• Abrasive Water Jet
Machining
• Abrasive Flow
Machining
• Magnetic Abrasive
Finishing
• Electric Discharge Machining Chemical
• Plasma Arc Machining • Electrochemical
• Laser Beam Machining Machining
• Electron Beam Machining • Chemical
• Ion Beam Machining Machining
• Biochemical
Machining

Dr. Harlal S. Mali, MNIT Jaipur Page 3

Some Applications Of AMP’s

1. Holes perpendicular to the wall (ECM)

2. Turbine blades (super alloys) with cooling holes (STEM), (diameter 1-

2mm and 10cm length)

3. When there is a change in diameter (STEM) (for e.g. 1 to 1.5mm).

Properties Of Work-Piece For Various AMP’s (Selection Of Right Amp?)

PROPERTIES PROCESSES

Electrically ECM, EDM, EBM

conductive

Electrically non USM, AJM, LBM

conductive

Non magnetic MAF, MRRF

Thermal LBM (not high reflectivity)

conductive

What Do We Need To Know When Studying A Manufacturing Process?

• Working Principles

• Equipments

• Process Parameters

• Applications

Dr. Harlal S. Mali, MNIT Jaipur Page 4

Classification of AMP’S

S.NO Energy Mechanism of Transfer Energy source Process

Type Metal removal Media

1. Mechanical Erosion High velocity Pneumatic/Hydraulic AJM,USM

particles /Ultranosic WJM,AFM

2. Electro- Ion Electrolyte High current ECM

chemical Displacement ECG

3. Chemical Ablative Reactive Corrosive agent CHM

Reaction Environment

4. Thermo- (a)Fusion Hot Gases Ionised Material IBM,PAM

electric

Electrons High(Right) Voltage EDM

(b)Vaporisation Radiation Amplified Light LBM

Ion Stream Ionised Material PAM

Dr. Harlal S. Mali, MNIT Jaipur Page 5

Physical Parameters of AMP’S

PARAMETE USM AJM ECM CHM EDM EBM LBM PAM

RS

Pd(V) 220 220 10 ------ 45 150,00 4500 100

0

Current 12 1.0 10,00 ------ 50 0.001 2(Avg20 500

0 0 Peak)
(Ampere) (AC) (PDC) (PDC) (DC)
(DC)

Power 2400 220 10000 ------- 2700 150 ----------- 50,00

0 0
(Watt) (AVG.
200
PEAK)

Gap (Mm) 0.25 0.75 0.20 ------ 0.025 100 150 7.5

Medium Abras Abras Electr Liqui Liquid Vaccu Air Argo

i-ves i-ves -olyte d m n
dielectr
in in chem
ic Or
Wate i-cal
jet
r Hydr
o-gen

Dr. Harlal S. Mali, MNIT Jaipur Page 6

Process capabilities of AMP’S

Process MRR Tolerance Surface Surface Corner

Finish Damage Radii
mm3/min (µm)
CLA µm Depth(µm) (mm)

USM 300 7.5 0.2-0.5 25 0.025

AJM 0.8 50 0.5-1.2 2.5 0.100

ECM 1500 50 0.1-2.5 5.0 0.025

CHM 15 50 0.4-2.5 50 0.125

EDM 800 15 0.2-12.5 125 0.025

EBM 1.6 25 0.4-2.5 250 2.50

LBM 0.1 25 0.4-1.25 125 2.50

PAM 75,000 125 Rough 500 -------

MILLING of 50,000 50 0.4-5.0 25 0.050

STEEL

Conclusion

• AMPs Leads to Enhanced Volumetric Material Removal Rate in Specific

Cases.

• With Dynamically Changing Materials and Product Development Industry

AMPs can lead to Compatible Mfg. Solutions.

• Computer Control of the Processes Resulting in Better Performance

• Application of Adaptive Control

– Unmanned Machining
Dr. Harlal S. Mali, MNIT Jaipur Page 7