2. Manufacturing
• Manufacturing Engineering or manufacturing
process are the steps through which raw
materials are transformed into a final product.
• The manufacturing process begins with the
product design, and materials specification from
which the product is made.
• These materials are then modified through
manufacturing processes to become the required
part.
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3. History
• The history of manufacturing can be separated
into two subjects:
• Human discoveries and invention of materials and
processes to make things
• Development of the systems of production.
• Processes like casting, hammering (forging),
and grinding, date back 6000 years or more.
• Since than time to time various advancements
have been made in the manufacturing
processes.
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4. • Several inventions of the Industrial Revolution,
greatly contributed to the development of
manufacturing like Watt’s steam engine John
Wilkinson’s boring machine, the factory system
for organizing large numbers of production
workers based on division of labor, etc.
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5. Manufacturing Processes
Manufacturing processes can be broadly
divided into two groups:
• Primary Manufacturing Processes : Provide basic
shape and size
• Secondary Manufacturing Processes : Provide
final shape and size with tighter control on
dimension, surface characteristics
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6. Material Removal Processes
• Material removal processes once again can
be divided into two groups:
• Conventional Machining Processes
• Non-Traditional Manufacturing Processes or non-
conventional Manufacturing processes
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7. • Conventional Machining Processes mostly
remove material in the form of chips by applying
forces on the work material with a wedge shaped
cutting tool that is harder than the work material
under machining condition.
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Non Conventional Machining
8. • Non-conventional 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.
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Non Conventional Machining
9. Characteristics of Conventional
Machining
The major characteristics of conventional
machining are:
• Generally macroscopic chip formation by
shear deformation
• Material removal takes place due to
application of cutting forces – energy domain
can be classified as mechanical
• Cutting tool is harder than work piece at
room temperature as well as under machining
conditions
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10. 10
Figure 1: Shear deformation in conventional machining leading to chip formation
11. Characteristics of Non
Conventional Machining
• The major characteristics of Non-conventional
machining are:
• Material removal may occur with chip
formation or even no chip formation may
take place. For example in AJM, chips are
of microscopic size and in case of
Electrochemical machining material
removal occurs due to electrochemical
dissolution at atomic level.
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12. • In NTM, there may not be a physical tool
present. For example in laser jet machining,
machining is carried out by laser beam.
However in Electrochemical Machining there
is a physical tool that is very much required
for machining.
• In NTM, the tool need not be harder than the
work piece material. For example, in EDM
(Electrical Discharge Machining), copper is
used as the tool material to machine
hardened steels.
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13. • Mostly NTM processes do not necessarily use
mechanical energy to provide material removal.
They use different energy domains to provide
machining. For example, in USM, AJM, WJM
mechanical energy is used to machine material,
whereas in ECM electrochemical dissolution
constitutes material removal.
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14. Classification of NTM processes
Classification of NTM processes is carried out
depending on the nature of energy used for
material removal.
• Mechanical Processes
•Abrasive Jet Machining (AJM)
•Ultrasonic Machining (USM)
•Water Jet Machining (WJM)
•Abrasive Water Jet Machining (AWJM)
• Electrochemical Processes
•Electrochemical Machining (ECM)
•Electro Chemical Grinding (ECG)
•Electro Jet Drilling (EJD)
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15. • Electro-Thermal Processes
• Electro-discharge machining (EDM)
• Laser Jet Machining (LJM)
• Electron Beam Machining (EBM)
• Chemical Processes
• Chemical Milling (CHM)
• Photochemical Milling (PCM)
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16. • Extremely hard and brittle materials or Difficult
to machine materials are difficult to machine by
traditional machining processes.
• When the work piece is too flexible or slender to
support the cutting or grinding forces.
• When the shape of the part is too complex.
• Intricate shaped blind hole – e.g. square hole of
15 mmx15 mm with a depth of 30 mm
• Deep hole with small hole diameter – e.g. φ 1.5
mm hole with l/d = 20
• Machining of composites.
Needs for Non Traditional Machining
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17. Product Technologies
• Any organization practicing advanced
manufacturing shall produce products
characterized as:
• Products with high levels of design
• Technologically complex products
• Innovative products
• Reliable, affordable, and available products
• Newer, better, more exciting products
• Products that solve a variety of society's
problems 17
18. Process Technologies
• The manufacturing process technologies described
in definitions of advanced manufacturing include:
• Computer technologies (e.g., CAD, CAE, CAM)
• High Performance Computing (HPC) for
modeling, simulation and analysis
• Rapid prototyping (additive manufacturing)
• High Precision technologies
• Information technologies
• Advanced robotics and other intelligent
production systems 18
19. • Automation
• Control systems to monitor processes
• Sustainable and green processes and
technologies
• New industrial platform technologies
(e.g., composite materials)
• Ability to custom manufacture
• Ability to manufacture high or low volume
(scalability)
• High rate of manufacturing
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