Physical and chemical material removal processes,

Additive manufacturing and

Joining
Chapter 6, 8 and 9

MANUFACTURING 1
Physical and chemical material
removal processes
 Non-Traditional Machining Processes
Thermal (EDM, Laserbeam machining)
Electrochemical Machining (ECM)
Chemical Machining (Etching)
Mechanical (Water-Jet cutting)
 Advantages (compared to “normal” machining)
Very complex geometry possible
High surface finish, small tolerances
No or very small tooling force on workpiece
Brittle / Hard/ material no problem
Electrical Discharge (Thermal) Machining

 Local heating of material

Spark erosion
Electron beam machining (Ion BM)
Laser beam machining
Plasma Arc cutting (above 20000 °C !)

 Material transport by cooling liquid

(or gas)
Spark erosion (EDM)
 Spark erosion
Electrode
Dielectric
Pulse generator

 Copper, Tungstencopper

 Sinker EDM
 Wire Erosion
Spark erosion
 Spark erosion
Elektrode
Dielectric
Pulsegenerator

 Copper, Tungstencopper

 Sinker EDM
 Wire Erosion How Wire EDM works
 Wire Erosion - Precise!
Spark erosion
 Spark erosion
Elektrode
Dielectric
Pulsegenerator

 Copper, Tungstencopper

 Sinker EDM
 Wire Erosion How Wire EDM works
 Wire Erosion - Precise!
Spark erosion (EDM – wire erosion
(EDM – wire erosion)
Electrochemical machining
 Material will be removed by electrolysis
Electrochemical milling
Deburring
Grinding and polishing electrochemical
machining
Elektrochemical Machining
 Material removed by elektrolysis
EDM - ECM Compared
 EDM:
Material removal by sparks
Non-conductive fluid (dielectric fluid)

 ECM:
Continuous current (electrolysis) causes material
removal
Conductive fluid
Higher rate of Material Removal than with EDM
Chemical machining
 Material will be removed due to a
chemical reaction
Surface resistant to chemicals

 Chemical milling
Large parts
 Photo etching chemical etching
High accuracy
Blasting
 High power density
Small grains that are translated with high
speeds
Blasting (Mechanical)
 Shot-peening
Shot peening – aircraft industry
 Abrasive blasting
Material reduction
Waterjet cutting
 demineralised water high pressure (400
Mpa) through small nozzle

 Abrasive WJC
Addition of powder with sharp edges (Alu-
Oxide (Al2O3)
Lasercutting
 Coherent beam
Light with fixed wave-length

 Pulse laser (e.g.. Eyes)

 Continuous laser

 Laser types
Laser
 Lasercutting
 Laserdrilling
 Laserwelding (LBW)
 Laserengraving
 Lasersoldering
Material Additive Processes
Material Additive Processes
3D Printing
 History (1984 – SLA)
2005 Opensource: Fablab, Makerspace
CAD file needed (STL, AMF)
○ Local solidification of material
Building a shape (complex shapes possible)
○ Solid modelling (CATIA, etc.)
○ Surface modelling
Applications
○ Medical
Material Additive Processes
 Grouping Categories of 3D Printing

Material Extrusion (ex. FDM)

Material Jetting (wax printing)
Directed Energy Deposition
Binder Jetting
Sheet Lamination
Powder Bed Fusion (ex. SLS, DMLS)
Vat Photopolymerisation (ex. SLA)
Additive process – 3D printing
 Process
FDM (Fused Deposition Modeling)
SLS (Selective Laser Sintering)
SLA (Introduction to Stereolithography)

 Quick from CAD to product, but slow in

mass manufacturing
Additive process – 3D printing
 Process
FDM (Fused Deposition Modeling)
SLS (Selective Laser Sintering)
SLA (Introduction to Stereolithography)

 Quick from CAD to product, but slow in

mass manufacturing
Materiaalaangroei-techniek
Additive processes
Additive Processes
Rapid prototyping
 Base Material
Liquid (synthetic resin, SLA)
Powder (SLS, metal “printing” possible)
Solid matter (PLA, ABS)
FDM, 3D FDM, 3D SLA

 Disadvantages (March 2024)

(Still!) reduced material selection
Not really suitable for mass production
Finishing by machining often necessary
Expensive !
Worst mechanical designs ever!
Joining (ch. 9)

Seam Embedding to cast in Kitting Clamping

Snap-fit Riveting Shrinking Welding Adhesive

Bonding

Lanced tab Stapling Pressing Bolting Soldering

Joining methods
 Classification of joining methods
Detachable
Limited detachable (e.g. riveted, soldered)
Non-detachable (welded, glued)

 Geometrical joints
Spot joint (1D)
Line joint (2D)
Surface joints (3D)
Joining methods
 Joining principle
Material joints
○ Welding joint
○ Soldering joint
○ Adhesive bonding joint
○ Kitting joint
Forming joints
○ Snap-fit joint
○ Shrink-fit joint
○ Rivets
○ Bolted joint (fasteners)
Joining methods
 Other
To cast in
Embedding
Insert-technique
Welding
 Not much welding !
 Classification of welding processes:
Low Rate of Heat Input
○ Oxyfuel welding (thermochemical welding)
(~3250 °C)
○ Shielded Arc welding Arc Welding
○ Flash welding
High Rate of Heat Input
○ Plasma Arc Welding (16500 °C !)
○ Laser beam welding
○ Spot and seam resistance welding RW
Welding
 Classification of welding processes:
Moderate Rate of Heat Input
○ Shielded metal arc welding SMAW (booglassen)
○ TIG welding (Gas Tungsten Arc Welding)
○ MIG welding (Gas metal arc welding) GMAW
○ MAG (Active Gas Metal Arc)
Soldering and adhesive bonding
 Joining with an overlap
Adhesive bonding -> organic material
Soldering -> metal alloy

 Lap

 Weakest link determines the strength

Adhesion / cohesion
- Material of part A
Adhesion A
- Joint between agent and
part A
- Bonding agent Cohesion

- Joint between agent and

part B Adhesion B
- Material of part B
Soldering and adhesive
bonding versus welding
 No change in material properties
 Applicable to more materials
 Tensile strength might be lower
 No extreme temperature
 Large lap surfaces
Soldering and adhesive bonding
 Surface finishing
 Curing of the agent
Soldering and brazing
 Soldering < 450 degrees Celsius
 Brazing > 450 degrees Celsius

 Flux is used to stimulated the capillary action,

promotes the flow of molten metal into the joint

 Soldering iron / torch brazing / furnace brazing

Adhesive bonding
 Normal curing
Easy to process
Strength is medium
 Chemical curing
Thermoplastics
Thermosetting

 One component Two component

Super Glu (Cyano Acrylate) acrylic-, epoxy
Adhesive bonding
 Fenol adhesive bonding and epoxy
adhesive bonding are used in aircraft
industry

 Application technique
 Temperature en humidity
 Autoclave (furnace with hot air and
pressurized)

 Kitting
Joints with joint elements
 Joint elements
shaft-hole joint

 Plastic deformation
Riveting and stapling

 Joints without plastic deformation

Bolt-nut joint / screws
Riveting
 Solid rivet
 Blind rivet
• Popnagel
Riveting (blind rivets)
 Construction can be reached on one
side
 One person can rivet
 Costs
 Lower strength than massive rivets
HC RACe
Joining without plastic
deformation (bolts and nuts)
 Labour intensive (bolt type dependent)
 Bolts or Screws (self-tapping/drilling)
 Used extensively in automotive industry
Torx bolts
Forming joints
 Elastic deformation
Snap-fit joints
 Plastic deformation
Riveting, Seaming and Lanced tab joints
The END!