Advanced Manufacturing Technologies [20ME53I] 2022-23

Week-1
Day 1: Session 1
1. Conventional Manufacturing Process
 Present an overview on Conventional manufacturing process
starting from procurement of raw materials to finished product
and delivery to the customer.

A conventional machining process is one in which the machining is done using the
traditional way, that is, without the use of any sophisticated methods. As a result, this
machining method is also known as traditional machining. Sharp point cutting tools,
such as the taper tool in the lathe machine for tapering, are employed in this
technique for machining. Because the cutting tool’s material is tougher than the work
pieces, and because the cutting tool is in direct contact with the work piece, there is
increased tool wear. For material removal, the cutting tool is employed against a
rotary or fixed work piece.

Fig.1 Manufacturing process flow chart.

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Manufacturing: The term manufacturing refers to the processing of raw materials or

parts into finished goods through the use of tools, human labor, machinery, and
chemical processing. Manufacturing allows businesses to sell finished products at a
higher cost than the value of the raw materials used. Large-scale manufacturing
allows for goods to be mass-produced using assembly line processes and advanced
technologies as core assets. Efficient manufacturing techniques enable manufacturers
to take advantage of economies of scale, producing more units at a lower cost.
 Process flow chart reflects the complete process from receiving to shipping of
product.
 Identify outsourced operations on the flow chart.
 Identify stations where special characteristics are verified.
 Include sequence numbers and required manufacturing/inspection stations.
 Include identification of unique and/or dedicated process equipment.
 Include rework/repair operations, including re-inspection of the product.
 Process flow diagrams include packaging, labeling and storage.

Day 1: Session 2
2. Introduction to Advanced materials.
Advanced materials are new materials with enhanced properties that are
intentionally designed for superior performance. The major scientific advances of
the 20th century, and a new understanding of atoms, laid the foundation for the
creation of advanced materials. Advanced materials are a complex scientific topic
that covers a huge variety of fields and applications.
It’s generally used to refer to new materials, with high-tech applications, that
were developed during the last few decades. Research and development of new
advanced materials for industrial applications is multi-disciplinary and can draw
on expertise in the fields of chemistry, physics, nanotechnology, ceramics,
metallurgy, and biomaterials – to name a few.
2.1 The Benefits of Advanced Materials
The general benefits of advanced industrial materials are straightforward. They
have the potential to bring us cheaper, more sophisticated, and more user-friendly
products. Household items, personal vehicles, and consumer durables are already
improving our quality of life, saving labor, and enhancing recreation.

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We are also seeing similar innovations in the workplace. Advanced industrial

materials are revolutionizing the devices, systems, and infrastructures that
previously defined and limited how we work and do business.

The reach and potential of businesses is expanding, as are methods of production,

print-on-demand technology, emerging quantum computers, the harvesting and
analysis of data, and the application of AI to design, monitoring, and problem-
solving. Whether we realize it or not, our working lives are already dependent to
an extent on advanced materials for industrial applications.

 Present a Video on components manufactured in Modern

Manufacturing Industries.

Modern or Non-traditional manufacturing processes is defined as a group of

processes that remove excess material by various techniques involving
mechanical, thermal, electrical or chemical energy or combinations of these
energies but do not use a sharp cutting tools as it needs to be used for traditional
manufacturing processes.
1) https://youtu.be/lTsvhSYstAE
2) https://youtu.be/2ArhhcgSsm0

 Present an Overview on Need, Classification and Features of

Advanced manufacturing technologies.

3. Need of Advanced Manufacturing Technologies:

Advanced-manufacturing technologies can boost innovation by allowing
manufacturers to create new kinds of products that can’t be made cost effectively
with conventional processes. They also permit manufacturers to produce high-quality
goods made to buyers exact specifications.
 Manufacturing is the basis for all economic activities and future growth of a
country
 At the beginning of 20th century, mass production using efficient machine tools
emerged in USA (Ford motors)
 After the second world war, new / advanced manufacturing processes came into
existence

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 Since 1950s, new technologies have been emerged – computerized numerical

control, flexible manufacturing systems, lean manufacturing, green
manufacturing, computer integrated manufacturing are some of those.
 Newer materials have been developed and their processing requires special
machine tools or special manufacturing process
 Therefore, there is a vital need to have more efforts to continuously advance
manufacturing technology for a better-off and more stable future.
4. Manufacturing processes classification:
There are six basic / fundamental classifications of manufacturing processes.
1. Metal casting or Molding: expendable mold and permanent mold
2. Metal Forming and Shearing: rolling, forging, extrusion, drawing, sheet
forming, powder metallurgy.
3. Material Removal Processes / Machining Processes: turning, boring, drilling,
milling, planning, shaping, broaching, grinding, ultrasonic machining, chemical
machining, electrical discharge machining (EDM), Abrasive flow machining
(AFM), abrasive jet machining (AJM), electrochemical machining, high-energy
beam machining, laser beam machining (LBM) etc.
4. Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding,
mechanical joining, plasma arc, plasma MIG, projection welding, ultrasonic,
electron beam welding, laser welding etc.
5. Finishing: (painting, anti-corrosion coatings, etc.)
6. Rapid Manufacturing: stereo-lithography, selective laser sintering, fused
deposition modeling, three dimensional printing, laminated object manufacturing,
laser engineered net shaping.
Features of Advanced Manufacturing Techniques:
 Efficient Production. ...
 Intelligent Production. ...
 Effective Organization. ...
 Additive Manufacturing. ...
 Advanced and Composite Materials. ...
 Robotics and Automation. ...
 Laser Machining and Welding. ...
 Nanotechnology.

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Day-2: Session 1

5. Advancement in Manufacturing Process.

 Discuss the Advancement in material technology leading to
advancement in Manufacturing Process.
1. Additive Manufacturing / 3D Printing
Additive manufacturing was actually developed in the 1980’s, but has picked up
more significant interest in the last few years. It covers any and all processes
involved in printing a 3-dimensional product, the reason it’s commonly referred
to as 3D printing. Additive manufacturing includes a technique called cold
spraying, which involves blasting metallic particles through a nozzle at high
speeds, binding particles together to form shapes. This creates a part by building
materials layer by layer through the control of a computer. Because the end result
is a high precision replica of an original design, there is less waste during the
production process and can save the manufacturer money.

Historically, additive manufacturing technology has been expensive and was

typically used by the “bigger fish” in the field. However, recent advancements
have enabled additive manufacturing to become more affordable, and it is
anticipated to become a common option for smaller manufacturers. 3-D printers
will continue to change the manufacturing landscape by creating more efficient
ways to manufacture custom parts and goods.
2. Advanced Materials
A report from the President’s Council of Advisors on Science and Technology
(PCAST) notes that “almost all the megatrends for the future — energy efficiency
or alternate energy devices, new materials to counter resource shortages, next-
generation consumer devices, and new paradigms in chemical safety and security
— depend heavily on advanced materials” and that these advanced materials “will
fuel emerging multi-billion dollar industries.” This includes advanced composites,
which have to date been largely restricted to use in a limited number of high-cost
applications. However, efforts are underway to develop manufacturing processes
that lower cost and speed production such that advanced composites are
integrated into a much wider range of products and applications in the coming
years.

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3. Cloud Computing
Cloud based computing uses network connected remote services to manage and
process data. Life in the cloud will gain momentum, but security concerns must
be continually addressed. Companies are increasing use of this technology across
various geographic locations to share data to make better business decisions.
Cloud Computing helps reduces costs, improve quality control and shorten
production times.

4. Internet of Things (IoT)

Many of us now can’t imagine life before the smart phone.welcome to the idea of
a smart manufacturing facility. Smart technology is not brand new, but it is
steadily developing into the wave of the future for manufacturing.
Imagine a workplace where connected equipment will be able to communicate via
the Internet and computerized manufacturing machinery will be able to “talk to
each other” and send/receive notifications about operating conditions. Once a
problem is detected, a notification is sent to other networked devices so the entire
process can be automatically adjusted. The end result will be reduced downtime,
improved quality, less waste and lower costs. This technology will lead to the
development of new types of positions for the manufacturing workforce.

5. Nanotechnology
Nanotechnology deals with matter between 1 and 100 nanometers; a nanometer is
one-billionth of a meter. Nanotechnology was traditionally used in the aerospace
and biomedical arenas, but is now being used to manufacture lightweight stronger
materials for boats, sporting equipment and auto parts, as well as being used in
creating personal care items such as eyeglasses. Nanostructure catalysts make
chemical manufacturing processes more efficient by saving energy, reducing
waste and will also have increased applications in healthcare and
pharmaceuticals.

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Day-2: Session 2
 Discuss and record the Application of these materials in making
components used in Aircraft, Cutting tools, high temperature
applications, Automobiles etc.

6. Materials used in High Temperature applications:

1. TITANIUM
Titanium is a lustrous transition metal which is silver in colour.Titanium alloys
have high tensile strength to weight ratio, good toughness, extraordinary
resistance to corrosion and an ability to withstand extreme temperatures of 600°C
plus. It is readily weldable and possesses good fabricability and effectiveness in
many challenging industrial applications.

2. TUNGSTEN
Tungsten is a steel-grey or silver-white refractory metal. Tungsten can be used as
the base metal for an alloy or as a supporting element. Tungsten provides high
hardness levels, a high resistance to heat and a high melting point. Tungsten is
commonly used in Combustion liners, Turbine exhaust components, Aircraft
cabin heaters, Transition Ducts & Industrial furnaces.

3. STAINLESS STEEL
Stainless steel is an iron base alloy with a minimum of 10.5% or more of
chromium as well as other metals like molybdenum and nickel. Stainless steel
alloys are known for their resistance to corrosion and heat, which makes them
ideal for use in the Aerospace, Automotive and Construction industries as well as
specific parts like Pressure Vessels, Steam Turbines, Boilers and Piping systems.

4. MOLYBDENUM
Molybdenum is a refractory metallic element that forms hard, stable carbides that
enhance hardenability, strength, toughness and resistance to wear and corrosion.
Molybdenum is frequently used in high-temperature alloys in steel, cast iron and
super-alloys in the Military and Defense Industry, Semiconductor and Speciality
Machine shops.

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5. NICKEL
Nickel is a naturally occurring silvery-white lustrous metal with a gold tinge. It is
malleable, ductile and has superior strength and corrosion resistance. Nickel is
frequently used in stainless steel and other alloys to make them stronger. Nickel
alloys are used in Gas Turbines, Power Generation, Aerospace, Speciality
Engineering and Electronics.
6. TANTALUM
Tantalum is a shiny, silvery metal that is soft when pure. It is virtually resistant to
corrosion due to an oxidised film on its surface. Tantalum is particularly useful in
high-temperature applications in Aircraft Engines as well as Electronic Devices.

7. Materials used in Automobile industry:

1. Steel: - The manufacture of steel has improved a great deal. Different parts and
areas of a car need different types of steel. Steel is the main materials in
manufacturing door panels, the chassis of the car, and the support beams. It is also
used in exhaust pipes and mufflers in the car. However, it is mostly used on the frame
of the car because of its strength. This means that it has a better ability to absorb
impact. The average car contains 2400 pounds of steel while and SUV has 3000
pounds of steel. Therefore, they help you remain safe on the road since it is a metal
that is responsible for the heavyweight and support of the cars.
2. Plastic: - Plastics used in car manufacturing are petroleum by-products (gas and
oil). Plastics are challengers to steel because of their prominence in car
manufacturing. They are malleable and still strong enough to hold the structure in
shape. Plastics constitute almost half of the total car parts, being the main component
in manufacturing the dashboard, door handles, pipes, and air vents. The durability,
versatility, and lightweight characteristics of plastics make them the ideal materials
for different parts.
3. Aluminum: - Among other metals, the light-weight and durability of Aluminum
make it perfect for specific car parts. It is also malleable, making it a common
material in car production. In 1970, it only accounted for 2% of the total components
of a car; today, it makes up to 15% of the total car parts.
The wheels, which are essential parts, are made of aluminum, replacing steel. Most
engine blocks are also made of steel even. Though it is not quite as durable as iron, it
is lighter, and this boosts performance.

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4. Rubber: - Rubber produces engine mounts, hoses seals wiper blades, and belts.
Like plastic, rubber is also cheap, durable, and flexible.
Therefore, it can function in a wide array of parts, and it will also handle heat well in
case the car heats up. What most people do not know is that a large percentage of the
rubber produced makes automobile parts.

5. Glass: - Currently, glass is used in navigation screens, back-up camera lenses, and
mirrors in your car. It helps the driver have a clearer view of what they are doing and
where they are going.
The windshields are made of laminated glass. Glass lamination assures users of the
highest safety levels, especially in the event of a crash.
Lamination involves putting a thin layer of vinyl between two glasses. This ensures
that there is not shutter when the glass is crushed.

6. Fiber glass: - Most people think that glass and fiberglass are the same material.
However, this is not true. Fiberglass is made of small thin strands of glass. It is mostly
air and not glass. When the glass is woven in these small sheets and resin painted on
it, smaller lighter things can be made. Fiberglass offers a lot of benefits in the
automotive industry. It is non-corrosive, so it helps replace steel in areas where steel
can get easily corroded.

7. Lead: - Lead is an excellent metal because it is heavy and helps to balance the
automobile. That is why most of the wheels are made of lead, aluminum, and parts of
fiberglass. The battery is also made of lead, which allows it to maintain safe
temperatures even when the car is heating up.
8. Copper: - Copper is mostly used in wiring the car and any other electronic parts.
The copper wires run throughout the car in different systems like the radio, safety
systems, and charging points. It is also found in starters.

9. Titanium: -Titanium is an expensive metal. This is why most companies refrain

from using it in their manufacturing process since newer and cheaper methods of
mining need to be developed. However, some companies use it in metallic parts where
steel and aluminum would traditionally be used. It mainly makes the cars look more
aesthetically pleasing.

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Day-3: Session 1

8. Non-Conventional Manufacturing Process.

 Discuss the Need and significance of non-Conventional machining
process.

Need and significance of Non-conventional machining process:

1. High strength alloys: When the hardness of the work material is often higher than
the cutting tool material or when it becomes necessary to use the machining process on
hardened material in such cases, the electro-chemical processes described would be
required.
2. Complex surfaces: When very complex surfaces in three dimensions need to be
produced, such as those in moulds and dies, where the work piece surface being the
hardened tool steel would be difficult to be processed by the conventional means, the
non-traditional process would be required.

3. Higher accuracies and surface finish: The accuracy and surface finish desired in
hard work piece materials require the conventional machining to be done very slowly
as well as adding a number of finishing processes, making the process very slow and
uneconomical.

4. Difficult geometries: In addition to the complex geometries, sometimes it is

required to produce difficult geometries such as long holes with length to diameter ratio
approaching that of 100, or very small size holes such as those with less than 0.1mm in
diameter which are almost impossible to be produced by conventional methods.

5.Automation: The relative economic comparison of these processes.

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 Discuss classification of Non-conventional machining process

9. Classification of Non- Conventional Machining Processes:
Different types of energy are used in this machining process to remove metal.
Because of which on the basis of energy use the unconventional machining
process can be classified into four categories:
 Mechanical Energy Based
 Electrical Energy-Based
 Chemical and Electrochemical Energy Based
 Thermal Energy-Based
 Mechanical Energy Based: In this process, mechanical energy is used to remove
unwanted materials like abrasive jet machining, water jet machining, ultrasonic
machining, etc.
 Electrical Energy-Based: In this process, an electrical spark is used to remove
unwanted material like electrical discharge machining, wire cut electrical
discharge machining, etc.
 Chemical and Electrochemical Energy Based: In this machining process,
chemical energy is used to remove unwanted materials like photochemical
machining, electrochemical machining, electrochemical grinding, etc.
 Thermal Energy-Based: In this machining, process heat is used to remove
unwanted material like plasma beam machining, laser beam machining, etc.

Types of Unconventional Machining Process

Some of the common types of unconventional machining processes are discussed
which are used for machining using different energy sources:
 Abrasive Jet Machining (AJM)
 Ultrasonic Machining (USM)
 Electrochemical Machining (ECM)
 Electrical Discharge Machining (EDM)
 Electron Beam Machining (EBM)
 Laser Beam Machining (LBM)
 Electrochemical Grinding (ECG)

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Day-3: Session 1
 Explain the Principle, Construction and Working of Ultrasonic
Machining Process (USM) using Videos.

Ultrasonic machining is one kind of grinding method. It is also known as ultrasonic

grinding or impact grinding. The term ultrasonic refers to waves of high frequency.
Human ear can hear the sound waves between 20 Hz to 20 kHz. This range is known
as audible range. The sound waves which have frequencies less than the audible
range are called infrasonic waves. The sound waves having frequencies above the
audible range are known as ultrasonic waves. The ultrasonic machining process is
suitable only for hard and brittle materials like carbides, glass, ceramics, silicon,
precious stones, germanium, titanium, tungsten, tool steels, die steels, etc.

PRINCIPLE OF USM
In this machining method, a slurry of small abrasive particles are forced against the
work piece by means of a vibrating tool and it causes the removal of metal from the
work piece in the form of extremely small chips.

CONSTRUCTION AND WORKING

Construction: The general arrangement of ultrasonic machining is shown in Fig.
 It consists of abrasive slurry, work piece, fixture, table, cutting tool, circulating
pump, reservoir, ultrasonic oscillator, leads, excitation coil, feed mechanism,
ultrasonic transducer, transducer cone, connecting body and tool holder.
 The ultrasonic oscillator and amplifier also known as generator is used to convert
the applied electrical energy at low frequency to high frequency.
 The transducer is made up of magnetostrictive material and it consists of a stack
of nickel laminations that are wound with a coil.
 The function of the transducer is to convert the electrical energy into mechanical
energy.

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Fig.1 Arrangement of ultrasonic machining process

 Generally tough and ductile tool material is used in this process. Low carbon
steels and stainless steels are commonly used as tool materials.
 The tool is brazed, soldered or fastened mechanically to the transducer through a
tool holder. Generally, tool holder is of cylindrical or conical in shape.
 The materials used for tool holders are titanium alloys, monel,aluminium,
stainless steel, etc.
 An abrasive slurry, usually a mixture of abrasive grains and water of definite
proportion (20-30 percent), is made to flow under pressure through the gap
between tool and workpiece. The gap between the tool and workpiece is of the
order 0.02 to 0.1 mm.
 The most commonly used abrasives are boron carbide (B4C), silicon carbide
(SiC), aluminium oxide (Al2O3), and diamond. Boron carbide is most commonly
used abrasive slurry, since it has the fastest cutting abrasive property.

Working:

 Electric power is given to ultrasonic oscillator and this oscillator converts the
electrical energy at low frequency to high frequency (20 kHz).
 High frequency power (20 kHz) from oscillator is supplied to the transducer.
 The function of the transducer is to convert the electrical energy into mechanical
vibrations. The transducer is made up of magnetostrictive material, which is

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excited by flowing high frequency electric current and this results in the
generation of mechanical vibrations. The vibrations are generated in the
transducer of the order of 20 kHz to 30 kHz and hence ultrasonic waves are
produced. Re
 These vibrations are then transmitted to the cutting tool through transducer cone,
connecting body and tool holder. This makes the tool to vibrate in a longitudinal
direction as shown in Fig
 Abrasive slurry is pumped from the reservoir and it is made to flow under
pressure through the gap between tool and work piece.
 In an abrasive slurry, when the cutting tool vibrates at high frequency, it leads in
the removal of metal from the work piece.
 The impact force arises out from the vibration of tool end and the flow of slurry
through the work piece tool gap causes thousands of microscopic grains to
remove the work piece material by abrasion.
 A refrigerated cooling system is used to cool the abrasive slurry to a temperature
of 5 to 6°C.
 The ultrasonic machining process is a copying process in which the shape of the
cutting tool is same as that of the cavity produced.

Day-3: Session 2
 Discuss the Characteristics of USM
10. CHARACTERISTICS OF USM
 Metal removal mechanism: Slurry of small abrasive particles is forced
against the work piece by means of a vibrating tool and it causes the removal
of metal from the work piece.
 Abrasive: Boron carbide (B4C), silicon carbide (SiC), aluminium oxide
(Al2O3) and diamond.
 Abrasive slurry: Abrasive grains + Water (20-30 percent)
 Vibration frequency: 20 to 30 kHz
 Amplitude: 25 to 100 μ
 Wear Ratio: 1.5:1 for tungsten carbide, 100: 1 for glass, 50: 1 for quartz, 75:
1 for ceramics and 1:1 for tool steel.
 Work material: Tungsten carbide, germanium, glass, ceramic,quartz, tool
steel, etc.

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