Advance Manufacturing Technology MDB 4213

Advance Manufacturing Technology

(MDB 4213)
A.P. Dr. Shahrul Kamaruddin  Extension: 7169  Room 17.03.31

ASSESSMENT

• Course Work 50%

Quizzes: 5%
Individual Assignments: 5%
Group Project: 10%
Test 1 & 2: 30%
Final Examination : 50%
• Total : 100%

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Advance Manufacturing Technology MDB 4213

Advance Manufacturing Technology (MDB 4213)

Course Outcomes:
At the end of the course, the students should be able to:
1
Identify the technology in advanced machining
processes.
2
Identify the technology in advanced joining and welding
processes.

3 Develop the knowledge in design and fabrication of

Students will be assessed using Bloom’s Taxonomy: additive manufacturing/layer manufacturing.
1. Cognitive/Knowledge
2. Affective/Attitude
3. Psychomotor/Skill
4
Identify the principle of production system and layout for
manufacturing

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Advance Manufacturing Technology (Lesson Plan)

1 2-3 4-6 7-9 10 - 12

Advanced Machining Advanced Joining and Rapid tools and Computer Integrated
Introduction Processes Welding Processes Prototyping Manufacturing System
o Fundamental of • Advanced Joining • Introduction Cellular manufacturing
advance • Types of machining • Adhesive • Subtractive processes FMS
manufacturing • Chemical bonding • Additive processes JIT
• Electrochemical • Mechanical • RP System Lean Manufacturing
• Laser / electron beam Joining • Rapid Tooling AI
• Water / abrasive jet • Advanced Welding • Rapid Manufacturing
• Electrical discharge Machining • Friction welding
(EDM) • Friction stir welding
• EDM Wire Cut
• EDM Die Sinker

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WHY IS ADVANCED MACHINING PROCESSES NEEDED?

There are situations where conventional machining processes are not satisfactory, economical, or
impossible for the following reasons:
• Material is very hard and strong, or too brittle.
• Work piece is too flexible, delicate, or difficult to fixture.
• Complex shapes.
• Surface finish and dimensional accuracy requirements.
• Temperature rise and residual stresses are not desirable.

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CONVENTIONAL VS NON-CONVENTIONAL MACHINING

Conventional Machining Non-Conventional Machining
Mostly remove material in the form of Remove excess material which involves
chips by applying forces on the work mechanical, thermal, electrical or chemical
material. energy or combinations of these energies.

A wedge shaped cutting tool used that is No sharp cutting tools is needed, the tool
harder than the work material. need not be harder than the work piece
material
Generally macroscopic chip formation by Microscopic chip formation, even in the level
shear deformation. of atomic size.
Use mechanical energy, like rotation to No physical tool presents.
provide cutting force

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NON-CONVENTIONAL MACHINING
Classification of NCM processes is carried out depending on the
nature of energy used for material removal
Chemical Processes Electro-Thermal Processes
• Chemical Milling (CHM) • Electro-discharge machining (EDM)
• Photochemical Milling (PCM) • Laser Jet Machining (LJM)
• Electron Beam Machining (EBM)
Electrochemical Processes Mechanical Processes
• Electrochemical Machining (ECM) • Abrasive Jet Machining (AJM)
• Electro Chemical Grinding (ECG) • Ultrasonic Machining (USM)
• Electro Jet Drilling (EJD) • Water Jet Machining (WJM)
• Abrasive Water Jet Machining (AWJM)

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GENERAL CHARACTERISTICS OF ADVANCED MACHINING PROCESSES

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FIGURE 27.4 Surface roughness and tolerances obtained in various machining processes;
note the wide range within each process

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CHEMICAL MACHINING

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CHEMICAL MACHINING
Local melting of material by suitable reagent or etchants.
• Machining of metal materials
• Removing speed of material independence on hardness
and on toughness
• Surfaces with complicated shape with high accuracy and
quality
• Here is no originated heat and mechanical influence
area
• Large areas – more economical than milling

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Reagents or etchants for chemical machining

• Ferrous metals – different acids,

• Copper, alloys of copper, heavy metals – chloride of ferrum FeCl3

• Aluminium, alloys of aluminium, light metals – caustic soda NaOH

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MATERIAL MACHINABILITY
Four groups of materials by chemical machinability:
• copper, bronze – easy they are melted, good
machinability by chemical machining,
• nickel, zinc, aluminium
• manganese, molybdenum
• chrome, gold, wolfram – they are hard melted, bad
machinability by chemical machining

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MASKANT OR RESIST
 Three major categories of chemically resistant masks are available for use in chemical machining
 Selection of proper maskant for a particular application is accomplished by evaluation of the job
with respect to six factors:
1. chemical resistance
2. Part configuration
3. quantity of parts
4. Cost
5. Ease of removal
6. required resolution

 Classification of maskant:
1. Cut and peel
2. Screen printing
3. Photoresist masks

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CUT AND PEEL

 Involve the use of relatively thick material which is scribed and removed to create a selective exposure to the etchant
 Neoprene, butyl or vinyl-based material
 Almost exclusively used for chemical milling of aircraft, missile and structural parts and components for chemical
industries
 Maskant is applied to the entire part to be processed by flow, dip or spray coating
 Materials are relatively thick in nature, being 0.001 to 0.005 inch thick in dry film form
 Materials are removed from areas to be etched by cutting the maskant with a scribe knife (generally with a template to aid
accuracy) and peeling away unwanted areas
 Because of the inherent nature of the maskant and the thickness of the coating, extremely high chemical resistance is
achieved, permitting etching depths of 0.5 in. or more
 Generally used where extremely critical dimensional tolerances are not required
 Used for parts that are extremely large, have many irregularities, require depth of etch in excess of 0.05 n and have
multiple steps in the removal areas
• The materials used for maskants afford flexibility in the processing –after a certain area has been etched, additional
maskant may be removed so that step etching is possible
• Only type of mask that can be easily rescribed to produce step etching

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SCREEN PRINTING
 Mask application technique that draws on conventional silk-screen printing technology
 A fine mesh silk or stainless steel screen, which has areas blocked-off to allow selective passage of the maskant is used
 The blocked pattern corresponds to the image that is to be etched
 The screen is pressed against the surface of the workpiece and the maskant is rolled on
 When the screen is removed, the maskant remains on the part in the desired pattern
 The maskant is ready for etching after it has been dried by baking
 Screen printing is a fast, economical masking method for high-volume production when high accuracy is not required
 The mask thickness is typically less than 0.05mm and so life in the etchant is relatively short, limiting the etching depth to
1.5mm
 Screen printing is desirable if part size is less than 1.2m x 1.2m; surfaces are flat or with only moderate contours; etch depth
does not exceed
 1.5mm per side; or when a high degree of accuracy is not required
 Screen printing is a fast, economical masking method for high-volume production when high accuracy is not required
 • The mask thickness is typically less than 0.05mm and so life in the etchant is relatively short, limiting the etching depth to
1.5mm
 • Screen printing is desirable if part size is less than 1.2m x 1.2m; surfaces are flat or with only
 moderate contours; etch depth does not exceed 1.5mm per side; or when a high degree of accuracy is not required

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PHOTORESIST MASKING
 Photoresist masking is so versatile and in such widespread use that it has almost become a separate
non traditional process
 Commonly known as photochemical machining (PCM), it is used to produce intricate and precise
mask on a work piece
 Capable of producing extremely high detail but lack the chemical resistance necessary for deep
etching
 Poor bonding of the resist film to the material being etched, unless the material is very carefully
cleaned prior to application of the resist
 Sensitivity to light and susceptibility to damage by rough handling and exposure to dirt and dust,
necessitating careful handling and a clean environment for successful operation
 More complicated processing than required by the scribe and peel maskants

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PHOTOCHEMICAL MACHINING (PCM)

 PCM is generally used for:
 1. Alternative to conventional stamping when intricate patterns or low production
volumes are involved
 2. Thin materials
 3. Parts requiring dimensional tolerances of the etchant resistant image tighter
than ±0.005 in
 4. Parts produced in high volume where the chemical resistance of the
photographic resists is adequate
• PCM are not generally used for:
 1. Depths in excess of 0.05in thick
 2. Parts larger than 3ft by 5ft
 3. Materials requiring the use of extremely-active etchants that will degrade
 or strip the photoresists

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WORK PIECE PREPARATION FOR CHEMICAL MACHINING

• Grease removal and surface cleaning – removing the allochemicals from
surface and oxidic coats too (Al alloys – AL2O3 coat), dipping into 5% medium
NaOH and next into 30% medium of acid of nitride,
• steeping – increasing of mask adhesion, dipping into medium H2SO4 and next
duochrom of patassic,
• masking – coating resisted on influence of diluent (resin, enamel) thickness till
2 mm.
• Mask drying – mask coating is drying 6 till 8 hours, it can be
accelerated in the furnace (small workpieces),
• Engraving of mask – into drying mask are created holes (hand
engraving, engraving by laser ...),

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FIGURE 27.3 (a) Schematic illustration of the chemical-machining process;

note that no forces or machine tools are involved in this process. (b) Stages in
producing a profiled cavity by chemical machining; note the undercut.

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Design Consideration Chemical Machining

 Avoid sharp corners, deep narrow cavities, steep tapers, folded
seams and porous work pieces
 Undercuts may develop
 Most of the work piece should be shaped by other processes to
speed production
 Variations may occur depending on humidity and temperature
 Computerized designs must be converted to a format compatible
with the photochemical artwork equipment

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ELECTRO-CHEMICAL MACHINING (ECM)

• Works on the principle of electrolysis –
accelerated chemilling
• Die is progressively lowered into work
piece as work piece is dissociated into ions
by electrolysis
• Electrolytic fluid flows around work piece
to remove ions and maintain electrical
current path
• Low DC voltage, very High current (700
amps) FIGURE 27.6 Schematic illustration of the
electrochemical machining process.

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FIGURE 27.7 Typical parts made by electrochemical machining.

Turbine blade made of a nickel alloy of 360 HB; note the shape of
the electrode on the right.

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DESIGN CONSIDERATIONS FOR ECM

• ECM is not suitable for producing sharp edges or flat
surfaces
• Flow of electrolyte can become difficult
• Designs should make provision for a small taper for
holes to be machined

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ELECTROCHEMICAL GRINDING
Combines electrochemical machining with conventional grinding
• Grinding wheel is the cathode
• Metal bonded wheel with diamond or Al2O3 abrasive
• Majority of material removal from electrolytic action (95%) therefore very low wheel
wear
• Much faster than conventional grinding

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DESIGN CONSIDERATIONS FOR ELECTROCHEMICAL

GRIDING
• Design should avoid sharp inside radii
• If the surface is to be flat, it should narrower than the
width of the grinding wheel

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TIME NEEDED FOR MACHINING

1. It is independence on the size of the
machined surface
2. It is depend on depth of machining only
3. Speed of outline 0,01 till 0,5 mm/min.
4. Mask resisted to outlining approximately
8 hours.

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APPLICATIONS
 Aerospace industries: machining gas  Facing and turning complex 3D
turbine blades, airframe component surfaces
fabrication, honey-comb aircraft panels,  Die sinking, particularly deep narrow
jet engine blade air foils slots and holes
 Manufacture of general machine parts:  Profiling and any odd shape
thin wall mechanical slotting, difficult to contouring
machine hollow shafts, chain pinions,  Multiple hole drilling
internal profile of internal cams, driving  Trepanning
joints, pump glands and impellers,  Broaching
connecting rod, hydraulic spools, gear  Deburring
wheels  Grinding
 Honing
 Cutting off

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Advantages
Ability to machine complex 3D curved surfaces without feed marks
 Machines complicated shapes in single pass
 Capable of machining metals and alloys irrespective of their strength and hardness
 Since metal removal is by metallic ion exchange, there are no cutting forces and the
work piece is left in a stress free state – very thin sections can be machined
 There is little or no tool wear – so large number of components can be machined
without replacing the tool
 Not subjected to high temperatures
 Burr free
 Good surface finish
 Good accuracy and tolerance
 Low machining time
 Low scrap
 Automatic operation
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Limitations
 Work must be electrically conductive
 Inability to machine sharp interior edges and corners
 Large power consumption and related problems (heavy initial investment)
 Post machining cleaning is a must to reduce the corrosion of the work piece and ECM machine
 Tool design is complicated and needs cut and try methods to achieve the final shape
 Although the parts produced by ECM are stress free, they are found to have fatigue strength or
endurance limit lowered by approximately 10-25%. So may require post treatment (shot peening)
to restore the strength especially for situations where fatigue strength is critical
 Additional problems related to machine tool requirements: power supply, electrolyte handling and
tool feed servo system
 High maintenance
 Can cause inter granular attack (IGA)
 High tooling and set-up costs

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ELECTRICAL-DISCHARGE MACHINING
(EDM)

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 Erosion of metals by
spark discharge
 Capacitor discharge is
between 50 and 380 V
 EDM can be used on
any material that is an
electrical conductor
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TYPES OF ELECTRODES
• Metallic electrodes
• Non metallic electrodes
• Combined metallic and non
metallic
• Metallic coating on insulators
• Most commonly used: Brass,
Copper, Graphite, Al alloys.

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EDM PROCESS
 CONTROLLED EROSION
 SPARK GAP FLOODED OR IMMERSED
UNDER THE DIELECTRIC FLUID
 SPARK DISCHARGE IS PRODUCED BY
THE CONTROLLED PULSING OF DIRECT
CURRENT
 DIELECTRIC FLUID IN THE SPARK GAP
IS IONIZED USING DIRECT CURRENT
 A SPARK DISCHARGE PASSES
BETWEEN THE TOOL AND THE WORK
PIECE

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EDM PROCESS
 EACH SPARK PRODUCES ENOUGH HEAT TO
MELT AND VAPORIZE A TINY VOLUME
 LEAVING A SMALL CRATER
 ENERGY CONTAINED IN EACH SPARK IS
DISCRETE
 IT CAN BE CONTROLLED
 MATERIAL REMOVAL RATE, SURFACE FINISH
AND TOLERANCE CAN BE PREDICTED

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TYPES OF EDM

SINKER EDM WIRE EDM

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SINKER EDM
 SINKER EDM, ALSO KNOWN AS CAVITY EDM OR VOLUME
EDM
 CONSISTS OF AN ELECTRODE AND WORKPIECE
SUBMERGED IN AN INSULATING LIQUID SUCH AS, OIL OR
OTHER DIELECTRIC FLUIDS
 THE ELECTRODE AND WORKPIECE ARE CONNECTED TO A
SUITABLE POWER SUPPLY
 THE POWER SUPPLY GENERATES AN ELECTRICAL
POTENTIAL BETWEEN THE TWO PARTS
 AS THE ELECTRODE APPROACHES THE WORKPIECE,
DIELECTRIC BREAKDOWN OCCURS IN THE FLUID,
FORMING A PLASMA CHANNEL, AND A SMALL SPARK
JUMPS

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WIRE EDM
 WIRE EDM, ALSO KNOWN AS WIRE-CUT
EDM AND WIRE CUTTING EDM
 A THIN SINGLE-STRAND METAL WIRE,
USUALLY BRASS, IS FED THROUGH THE WORKPIECE,
SUBMERGED IN A TANK OF DIELECTRIC FLUID,
TYPICALLY DEIONIZED WATER
 WIRE-CUT EDM IS TYPICALLY USED TO CUT PLATES AS
THICK AS 300MM AND TO MAKE PUNCHES, TOOLS,
AND DIES FROM HARD METALS THAT ARE DIFFICULT
TO MACHINE WITH OTHER METHODS
 THE WIRE, WHICH IS CONSTANTLY FED FROM A
SPOOL, IS HELD BETWEEN UPPER AND
LOWER DIAMOND GUIDES
 THE GUIDES, USUALLY CNC-CONTROLLED, MOVE IN
THE X–Y PLANE

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ADVANTAGES
COMPLEX SHAPES THAT WOULD OTHERWISE BE DIFFICULT TO PRODUCE WITH
CONVENTIONAL CUTTING TOOLS
EXTREMELY HARD MATERIAL TO VERY CLOSE TOLERANCES
VERY SMALL WORK PIECES WHERE CONVENTIONAL CUTTING TOOLS MAY
DAMAGE THE PART FROM EXCESS CUTTING TOOL PRESSURE
THERE IS NO DIRECT CONTACT BETWEEN TOOL AND WORK PIECE. THEREFORE
DELICATE SECTIONS AND WEAK MATERIALS CAN BE MACHINED WITHOUT ANY
DISTORTION
A GOOD SURFACE FINISH CAN BE OBTAINED
VERY FINE HOLES CAN BE DRILLED

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DISADVANTAGES
 THE SLOW RATE OF MATERIAL REMOVAL
 POTENTIAL FIRE HAZARD ASSOCIATED WITH USE OF COMBUSTIBLE OIL BASED
DIELECTRICS
 THE ADDITIONAL TIME AND COST USED FOR CREATING ELECTRODES FOR RAM/SINKER
EDM
 REPRODUCING SHARP CORNERS ON THE WORKPIECE IS DIFFICULT DUE TO ELECTRODE
WEAR
 SPECIFIC POWER CONSUMPTION IS VERY HIGH
 “OVERCUT” IS FORMED
 EXCESSIVE TOOL WEAR OCCURS DURING MACHINING
 ELECTRICALLY NON-CONDUCTIVE MATERIALS CAN BE MACHINED ONLY WITH SPECIFIC
SET-UP OF THE PROCESS

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LASER-BEAM MACHINING

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LASER-BEAM MACHINING
Focuses optical energy on the work piece
The high focus high density energy melts
the material
Rough surface and has heat affected areas
Oxygen maybe added to the laser for
increase of energy, doing this leave a oxide
free edge which improves welding
Lasers are also used for etching

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FIGURE 27.15
(a) Schematic illustration of the laser-beam machining process.
(b) and (c) Examples of holes produced in nonmetallic parts by LBM.
(d) Cutting sheet metal with a laser beam.
Source: (d) Courtesy of Rofin-Sinar, Inc.

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General Applications of Lasers in Manufacturing

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ELECTRON-BEAM MACHINING

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Electron Beam Machine

 The energy source in EBM
is high-velocity electrons
that move from 50% to
80% the speed of light!
 It is a lot like Laser beam
Machining but needs a
vacuum because it puts of
harmful x-rays, so is only
used by trained personnel

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Material processing by electron beam

• High intensity of electron beam energy (109
W/cm2),
• High speed of electrons (1,6 108 m/s),
• Small surface of impact (0,003 mm2),
• Electrons in the crash with particular atoms
(molecules) of the base material transfer
their energy.
• Depth of conjuction – depth in that
electron transfer completely their energy.

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PROCESSING BY ELECTRON BEAM

• Cutting
• Micromachining
• Drilling
• Marking, describing and engraving
• Welding
• Thermal processing

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• Plasma arc cutting is a type of

EBM
• Its temp. gets from 9400 C to
17,000 C
Which makes the process much
faster the LBM and EDM with
better products
• EBM have limited machining
because of the vacuum capacity

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Drilling by electron beam

• Small holes (5 m) with high accuracy
(1m),
• Holes above 0,25 mm – beam tipping
• Bigger holes (above 2-5 mm) –
trepanation accuracy 0,025 mm
• They are used in production of filtre and
riddles (big number of small holes).
• Fast production of accurately
(dimensionally and positioning) holes.

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Welding by electron beam

• Kinetic energy of impacted electrons is
used for material melting,
• Possibility to chemical weld of active
material in the vacuum room,
• Big depth of burnout,
• Minimum thermal influenced area,

• Needed continuous directing of beam

energy from 0 to maximum

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Water Jet Machining

• Cut a variety of metal and nonmetal material up

to 6-ft. x 12-ft. x 12-in. thick
• Reduce machining time by as much as 70%
• Provide a burr-free finished edge
• Leave no heat-affected zone (HAZ)
• Reduce waste material
• Eliminate costly set-up time

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WATER JET MACHINING

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FIGURE 27.18 (a) Schematic illustration of the water-jet machining process. (b) A
computer-controlled water-jet cutting machine. (c) Examples of various nonmetallic
parts produced by the water-jet cutting process.
Source: Courtesy of OMAX Corporation.

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• The water jet is the most versatile

machine on the market today
• The water leaving the nozzle is from
400 MPa to 1400 MPa
• The diameter of the spray is .05mm -
1mm
• It is used in lots of industries from
wood, to food processing, metal
working
• The material is wet very little
• It is environmentally safe process

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• Water jet cutters have

no start holes
• The jets have an
extremely high velocity
• No heat during cutting
• Very intricate designs

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Abrasive water jet machining

• The same thing is water jet but
with added abrasive particle, such
as silicon carbide or aluminum
oxide
• This increases the material rate
removal of the product
• The machine is a little more
complicated cause it needs to mix
the contents

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FIGURE 27.19 (a) Schematic illustration of the abrasive-jet machining

process. (b) Examples of parts made by abrasive-jet machining, produced
in 50-mm (2-in.) thick 304 stainless steel.
Source: Courtesy of OMAX Corporation.

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Advance Manufacturing Technology MDB 4213

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Advance Manufacturing Technology MDB 4213

References

Kalpakjian, Schmid, Sekar, Manufacturing Engineering and

Technology © 2014

A.P. Dr. Shahrul Kamaruddin Jan 2018 Page 69

Advance Manufacturing Technology MDB 4213

A.P. Dr. Shahrul Kamaruddin Jan 2018 Page 70