DEMO.pptx

BITS Pilani
Hyderabad Campus
Demo on Advance Manufacturing process Lab

BITS Pilani, Hyderabad Campus
What is Manufacturing
Manufacturing is the processing of raw
materials or parts into finished goods through
the use of tools, human labor, machinery, and
chemical processing.
Efficient manufacturing techniques enable
manufacturers to take advantage of economies of
scale, producing more units at a lower cost.

Classification of manufacturing process

Advanced manufacturing process
Why you need advance manufacturing process
 Limitation of conventional machining methods
 High production rate while processing difficult machine materials
 Low cost of production
 Precision and ultra precision machining
 High surface finish
 Machining of complex parts

 Electro discharge machining (EDM)
 Wire cut EDM
 Electro chemical machining (ECM)
 Compute numerical control (CNC)
 3D Printing
 Micro Machining
Advanced manufacturing process

1. Study and Prepare a program by ELCAM software and cut the profile by using CNC Wire cut
EDM
2. Study and demonstration of Electro Chemical Machining (ECM).
3. To produce a part using 3D printing technique.
4. Prepare a CNC manual part program and create the product by using CNC Lathe m/c.
5. Generate the tool path (program) by using CREO Manufacturing tool and create the product by
using CNC Milling m/c.
6. Experimental Analysis of Micro-Milling of Hardened H13 Tool Steel
7. Modelling and Simulation of Micro Cutting.
8. Determine the Extreme Pressure (EP) wear preventive (WP) characteristics of lubricants by
using Four Ball Tester
9. Characterizing the dry sliding friction and wear behavior of materials using Pin On Disk
Tribometer.
Lab experiments

1.Electro discharge machining (EDM)
OBJECTIVE:
 Study and Prepare a program by ELCAM software and cut the profile by using
CNC Wire cut EDM.

Principle
 Metal is removed by producing powerful electric
spark discharge between the tool (cathode) and the
work material (anode)
 Also known as Spark erosion machining or electro
erosion machining
 Machining action forms a gap between the part and
electrode (tool) which causes a spark which removes
the material from work piece
 Electrode is (-) negative and part is (+) possitive
 Electrode can be made form brass, copper, graphite
Introduction to EDM

EDM has the following advantages:
1. Cavities with thin walls and fine features can be produced.
2. Difficult geometry is possible.
3. The use of EDM is not affected by the hardness of the work material.
4. The process is burr-free.
Electrical Discharge Machining (EDM)

 The spark theory on a wire EDM is
basically same as that of the EDM
process.
 Wire EDM is a process whereby a thin
wire is used as an electrode to cut
along a programmed path. The
workpiece is submerged in a dielectric
fluid (which increases the water's
resistivity) allowing for the generation
of an arc at the wire, which in turn
disintegrates the workpiece.
Wire Cut Electrical Discharge Machining
(WC-EDM)

(WC-EDM)
0.005- 0.05mm

Dielectric Fluid
– Fluid medium which doesn’t conduct electricity
– Dielectric fluids generally used are paraffin, white
spirit, kerosene, mineral oil
– Must freely circulate between the work piece and
tool which are submerged in it
– Eroded particles must be flushed out easily
– Should be available @ reasonableprice
– Dielectric fluid must be filtered before reuse so that chip
contamination of fluid will not affect machining accuracy
(WC-EDM)

(WC-EDM)
• Applications
– Best suited for production of gears, tools, dies, rotors, turbine blades and
cams
• Disadvantages
– Capital cost is high
– Cutting rate is slow
– Not suitable for large workpieces

2.Electro chemical machining (ECM)
OBJECTIVE:
 (E2) Study and demonstration of Electro Chemical Machining (ECM)

• ECM is one of the recent and most useful machining process.
• In this process, electrolysis method is used to remove the metal from the
workpiece.
• It is best suited for the metals and alloys which are difficult to be machined
by mechanical machining process.
Introduction ECM

The electrochemical machining system has
the following modules:
• Power supply
• Electrolyte filtration and delivery system
• Tool feed system
• Working tank
Construction of ECM

• The tool and the workpiece are held close to each other
with a very small gap (of 0.05 to 0.5mm) between them
by using a servo motor.
• The electrolyte from the reservoir is pumped at high
pressure and flows through the gap between the workpiece
and the tool at a velocity (of 30 to 60m/s).
Working Principle

• A D.C voltage about 5-30 volts is applied between the
tool and the work piece.
• Due to the applied voltage the current flows through
the electrolyte with +ve charged
ions and –ve charged ions.
• The +ve charged ions moves towards the tool
(cathode) while –ve ions moves towards
the workpiece (anode).
• The electro chemical reaction takes place due to the
flow of ions and it causes the removal
of metal from the workpiece.
Working Principle

Electrolysis:
– D.C voltage of about 5-30V is applied between the tool and work piece.
– So the current in water flows through the electrolyte (solution of NaCl)
with charged ions.
–Many chemical reactions occurs at the cathode and the anode.
Working Principle

 Die Sinking
 Profiling and contouring
 Trepanning
 Grinding
 Drilling
 Micro-machining
 Pulsed ECM
Applications

ECM is well suited for the
machining of complex
two-dimensional shapes
Delicate parts maybe made
Difficult-to machine geometries
Poorlymachinable materials may be
processed
Little or no toolwear
Disadvantages
Initial tooling can be
timely andcostly
Environmentally
harmful by-products
Complicated tool design
Large power consumption
Advantages and disadvantages

3. 3D Printing
OBJECTIVE:
 To produce a part using 3D printing technique.

What is 3 D printing/Additive Manufacturing ?
• The construction of a three-dimensional object from a CAD
model or a digital 3D model.
• It is method converting virtual 3D model into physical
model. Where 3D object is created by laydown successive
layers of materials
[2]
Types of 3D Printing method
 Fused deposition method
 Stereolithographic
 Laminated Object Manufacturing.
 Selective Laser Sintering (SLS).
 Selective Laser Melting (SLM).

What is
FDM?
Fused Deposition Modeling (FDM), a layer-wise 3D
printing technology, has been developed by
Stratasys© for fabricating complex geometrical parts .
The materials used are thermoplastic polymers and
come in a filament form.
Examples of thermoplastic used for FDM are PVA ,PLA
ABS ,NYLON/POLYAMIDE ,PP ,PE ,PEEK…
FDM Process

1 Filament spools
2 Main filament
3 Support filament
4 Extrusion head
5 Printed part
6 Support structure
7 Build platform
A Typical FDM Machine

Summary of a basic FDM process.
Step 1: Import of CAD data in .stl
(STereoLithography) format into
Slicing Software
Step 2: Slicing of the CAD model into
horizontal layers
Step 3: Generation of .gcode file.
Step 4: FDM fabrication process using
a filament modeling material to build
actual physical part in an additive
manner layer-by-layer
Step 1 Import of
CAD data in .stl
format
Import Slicing Software and set
printing parameter
Generation of
.gcode file.
Layer by layer
printing of
finial part
Outline of a FDM production

Outline of a FDM production line
Z
X
Y

Outline of a FDM production
Polymer Filament
Polymer extrudate

Part Orientation Raster width Raster Angle
The orientation of the
part is defined as how the
part should be positioned
when produced
Raster width or road width which refers
to the width of the deposition path related
to tip size. It also refers to the tool path
width of the raster pattern used to fill
interior regions of the part curves .
Raster angle or orientation
which is measured from the X-
axis on the bottom part layer.
Also, it refers to the direction of
the beads of material (roads)
relative to the loading of the part.
The deposited roads can be built
at different angles to fill the
interior part.
Processing Parameters

The layer thickness which is recognized
as the height of the deposited slice from
the FDM nozzle
The air gap parameter which is defined as the space
between the beads of deposited FDM material

Rectangular - Standard infill pattern for FDM prints. Has
strength in all directions and is reasonably fast to print.
Requires the printer to do the least amount of bridging
across the infill pattern.
Triangular or diagonal - Used when strength is needed in
the direction of the walls. Triangles take a little longer to
print.
Wiggle - Allows the model to be soft, to twist, or to
compress. Can be a good choice particularly with a soft
rubbery material or softer nylon.
Honeycomb - Popular infill. It is quick to print and is very
strong, providing strength in all directions.
Infill geometry
For a standard print, infill is simply printed as an angled hatch or a
honeycomb shape. The four most common infill shapes are:
Infill percentage
FDM prints are typically printed with a
low-density infill. Most FDM slicer
programs will by default print parts with a
18%-20% infill which is perfectly adequate
for the majority of 3D printing applications.
This also allows for faster and more
affordable prints.
Infill percentage ranging from 20% (left), 50% (center) and 75% (right)

Factors effecting the final properties
of the printed parts
• Layer thickness
• Raster angle and width
• Infill Percentage and pattern
• Number of contours
Machine Properties
• Nozzle Diameter and temperature
• Print bed and chamber temperature
• Printing speed
Material properties
• Type of polymer
• Melting point
• Viscosity at printing temperature
Final properties of the
printed parts printed parts
• Mechanical
• Thermal
• Electrical properties

A B
Type Of Extrusion system used
A. Direct extrusion system
Direct extruders, as the name implies, are
directly attached to the hot end and are a
part of the print head.
B. Indirect Extruder or Bowden extrusion system
The difference between Direct and Bowden extruders is the
location of the extruder in relation to the hot end.
The opposite of Direct extruders, Bowden
extruders are not attached to the hot end or print
head. Instead, the extruder is removed from the
print head and is most often attached to the printer
body. The filament is then fed to the hot end using
a Bowden tube

Benefits, Limitations & Application of 3D printing
Benefits Limitations
Geometric complexity at no extra cost Lower strength & anisotropic material properties
Very low start-up costs Less cost-competitive at higher volumes
Customization of each and every part Limited accuracy & tolerances
Low-cost prototyping with very quick turnaround Post-processing & support removal
Large range of (specialty) materials
Application
Biomedical
Aerospace, Automobile
Tooling
Electrical and Electronic
Energy Storage

3D printing(FDM) offers great geometric flexibility and can produce custom parts
and prototypes quickly and at a low cost, but when large volumes, tight tolerances
or demanding material properties are required traditional manufacturing
technologies are often a better option.
To Summarize

Printers in our workshop
Flashforge Inventor 2 Raise 3D N2Plus

Printers in our workshop
Manufacturer RAISE3D
Layer Thickness (microns) 10 – 300
Printing Technology Fused Filament Fabrication
Volume Build Volume W x D x H (mm) 305 x 305 x 610
Resurrection System Resume Printing Function after power interruption
Advertised Manufacturer Speed (mm/s) 10-150 mm/s
Advertised Manufacturer Material
PLA / PLA+ / ABS / PC / PETG / R-flex / TPU / HIPS / Bronze-filled /
Wood-filled
Nozzle Temperature up to 300°C / 572°F
Heated Bed up to 110°C / 230°F
Connectivity WIFI, SD Card, USB, Ethernet
Enclose Machine Yes
Dual Extrusion Yes
Nozzle Diameter (mm) 0.4
Propriatery filament No
Filament Diameter (mm) 1.75
Printer Software IdeaMaker
Workstation Compatibility Windows, Mac OS
File Input Format STL / OBJ
Printer Volume W x D x H (mm) 616 x 590 x 960
Weight Volume (kg) 50

Applications

4. CNC Lathe
OBJECTIVE:
 Prepare a CNC manual part program and create the product by using
CNC Lathe m/c.

Introduction CNC
 Form of programmable automation.
 Mechanical actions of machine tool are controlled by
program.
 The program is in form of alphanumeric data.
 After a job is finished the program of instructions can
be changed to process a new job.

*The first NC machines were built in the 1940s and 1950s by Prof. John T
Parson.
*CNC machine came into existence after evolution of computer around 1980.
*Modern CNC Machine are improving further as the technology is changing
with a variety of functions according to applications.
History of CNC

*The tool or material moves automatically.
*Tools can operate in 1-5 axes.
*Larger machines have a machine control unit (MCU) which
manages operations.
*Movement is controlled by motors (actuators).
*Feedback is provided by sensors (transducers)
*Tool magazines are used to change tools automatically.
Features of CNC machine

Computerized Numerical Control (CNC)
• The machine tool system in which all the manufacturing operations are controlled by a set of instructions
given to it using a computer.
Part programming:
• The sequence of instructions given to a machine control unit to perform the required machining operation.
• Components of CNC system
Part programming
Machine control
unit
Machine tool

• The part programming contains the list of coordinate values along the X, Y and Z directions of
the entire tool path to finish the component.
• The program contains the information such as feed, speed and depth of cut etc.
• Each of the necessary instructions for a particular operation given in the part program is known as
an NC word.
• A group of such NC words constitutes a complete NC instruction, known as NC block.
• A group of NC blocks together is known as NC part programming.
Part programming of CNC machine

CNC Part programming
The Part program is written using various codes which can
be understood by the CNC machine tool.
Some of the common codes used in the part program are:
N: Block sequence number
G: Preparatory Function
M: Miscellaneous function
F:Feed function
S: Spindle speed function
T: Tool function
R: Radius of arc
X, Y, Z …. Represents the axes of the machine.

• G-codes, also called preparatory codes, designated by letter G. Generally it instructs the machine tool what
type of action to perform, such as:
 Rapid movement (transport the tool as quickly as possible in between cuts)
 Controlled feed in a straight line or arc
 Set tool information such as offset
 Switch coordinate systems
• Example: Linear Interpolation
• Syntax: Code [axis word] [optional feed word]
G00 X0 Y0 (get into start Position
G01 X1.2 Y0.3 F3.0 ; Moves to (1.2, 0.3) at 3units/min
Preparatory functions (G- codes)
(0,0)
(1.2,0.3)

Preparatory functions (G- codes)
G00 Rapid Transverse
G01 Linear Interpolation
G02 Circular Interpolation, CW
G03 Circular Interpolation, CCW
G17 XY Plane,G18 XZ Plane,G19 YZ
Plane
G20/G70 Inch units
G21/G71 Metric Units
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation (plus)
G43 Tool length compensation
(plus)
(minus)
cancel
G80 Cancel canned cycles
G81 Drilling cycle
G82 Counter boring cycle
G83 Deep hole drilling cycle
G90 Absolute positioning
G91 Incremental positioning

• Miscellaneous function or "M-Codes," control the working components that activate and deactivate
coolant flow, spindle rotation, the direction of the spindle rotation and similar activities.
• Codes:
M 02 : Program End
M 03: Spindle rotation clockwise
M 04: Spindle rotation counter clockwise
M 05: Spindle stop
M 06: Tool change
M 08: Coolant on
M 09: coolant off, etc.
Miscellaneous functions (M-Codes)

Basic terminology of machining
Speed
Feed
Depth of cut
Speed
Depth of cut
Work Piece

*Controlled by G and M codes.
*These are number values and co-ordinates.
*Each number or code is assigned to a particular operation.
*Typed in manually to CAD by machine operators.
*G & M codes are automatically generated by the computer software.
How CNCworks

1. Prepare the drawing of the job required as per the dimensions.
2. Write a part program for the job to be machined on the CNC turning machine.
3. Place the job in the chuck and set the tool according to the operation to be
performed on the machine.
4. Close the door of the CNC machine after the placement of the workpiece.
5. Start the machine and run the program.
6. Remove the job after completion of the work.
Procedure

5. CNC Milling
OBJECTIVE:
 Generate the tool path (program) by using CREO Manufacturing
tool and create the product by using CNC Milling m/c..

Creo-Mfg user interface
• A 100 mm x 50 mm size block modelled in Creo software.

Text written on the modelled block
• This software allows the user to design the anything as per their requirement.

Selection of tool type and diameter
• Creo-Mfg. tool allows the user to select the type and size of the tool for machining operations.
• The selected tool is allowed to move over the design or text present on the block which automatically generates
the tool path.

Generation of part program for tool path
• Finally the generated tool path at the
back end of the Creo-Mfg. software is
imported into the CIMCO software
and checked it before going for the
actual machining operation.

OBJECTIVE:
Experimental Analysis of Micro-Milling of Hardened H13 Tool
Steel
6.Micro Milling

 Micromachining is the basic technology for fabrication of micro-
components of size in the range of 1 to 500 µm. Their need arises
from miniaturization of various devices in science and
engineering, calling for ultra-precision manufacturing and micro-
fabrication.
 Definition: material removal at micro/ Nano level with no
constraint on the size of the component being machined
 Removal of material in the form of chips having the size in the
range of microns.
 Creating micro features or surface characteristics (especially
surface finish) in the micro/ Nano level.
Introduction

 Final finishing operations in manufacturing of precise parts are always of concern
owing to their most critical, labour intensive and least controllable nature.
 In the aera of nanotechnology, deterministic high precision finishing methods are of
utmost importance and are the need of present manufacturing scenario.
 The need for high precision in manufacturing was felt by manufacturers worldwide
to improve interchangeability of components, improve quality control and longer
wear/fatigue life.
Why Micro Machining

Present day High-tech Industries, Design requirements are stringent.
 Extraordinary Properties of Materials (High Strength, High heat Resistant, High
hardness, Corrosion resistant etc.)
 Complex 3D Components (Turbine Blades)
 Miniature Features (filters for food processing and textile industries having few tens
of microns as hole diameter and thousands in number)
 Nano level surface finish on Complex geometries (thousands of turbulated cooling
holes in a turbine blade)
 Making and finishing of micro fluidic channels (in electrically conducting & non
conducting materials, say glass, quartz, &ceramics)
Why Micro Machining

Photolithography
Etching
Silicon Micromachining
LIGA
Mechanical Micromachining
DIFFERENTMICROMACHININGTECHNIQUES

BITS Pilani – Hyderabad campus
400 μm tungsten carbide
end mill
Micro-heat exchanger [Filiz et al. (2007)]
Pocket Size: 2.5mm
Wall height: 500micron
Thickness: 100 micron
Source: www.nist.gov
Spiral channel for micro-fluidic
application
Micro Fluidic channels
(Filiz et al 2007)

Details of High Speed Micromilling Machine
Fig. (a) HSMC, (b) Details of the Machining Centre
(a)
(b)
Parameter Description/Value
Make MicroMach
XYZ table Stepper motor controlled
Worktable
Granite frame with maximum 100 mm
x 100 mm travel length in X & Y
respectively
Maximum
Speed
80,000 rpm
Lubrication Mixture of air and oil

Code Generation
• Commercial softwares like CREO, CNC code generators, CNC
simulators etc. can be used to generate codes for required profile
• We can verify our manual codes using available online simulators
like https://nraynaud.github.io/webgcode/
Write your
code here
Simulation of
tool path and
generated
profile

Lets take a look at Micro-tool……

Some Machined Surface – Acrylic Plate
Profile-1 Profile-2
Profile-3
• All these profiles were produced
using cutting tool of 1mm
diameter at 35,000 rpm with
6mm/min feed rate.
• Depth of cut was 800 microns

OBJECTIVE:
Modelling and Simulation of Micro Cutting.
7.Modeling and simulation

OBJECTIVE:
Characterizing the dry sliding friction and wear behavior of
materials using Four ball test.
8.Four ball test

Four Ball Tester, also known as Shell four ball tester,
is used to characterize lubricants properties, such as
wear prevention (WP), extreme pressure (EP) and
frictional behavior (various testing standards are
listed below).
The tester consists of four balls in the configuration
of an equilateral tetrahedron, as shown in the figure
below. The upper ball rotates and is in contact against
the lower three balls, which are held in a fixed
position.
Four ball Test

Four Ball Wear Test
Four ball test can also be used to measure the performance of the lubricant with respect to
wear. During the test the upper ball is rotated against the rest of the balls that are fixed.
The load is performed at fixed conditions (load, temperature, speed, etc.), unlike the
extreme pressure test.
After the test, the wear scar measurements are performed using for example optical
profilometry and can be used to judge the performance of a lubricant with respect to wear.
Friction force is also measured during this test and therefore, can also be analyzed.

Tribological characterisation
• Pin on Disc Tribometer (mainly for solids)
• Four Ball Tester (mainly for lubricalnts)
BITS Pilani, Hyderabad Campus 72

OBJECTIVE:
Characterizing the dry sliding friction and wear behavior of
materials using Pin On Disk Tribometer.
9.Pin on Disc Test

Pin on Disc Tribometer
• The Pin on Disc Friction & Wear Test Rig is primarily intended for determining the tribological
characteristics of wide range of materials under various conditions.
BITS Pilani, Hyderabad Campus 74
• Friction and wear behavior
can be evaluated over a wide
range of varying load and
speed.
• Useful to characterize the
tribological performance of
bulk materials, coatings and
lubricants accurately.

Pin on disk tribometer
Schematically, the pin on disk test is depicted in the figure
above. The stationary pin is pressed against rotating disk
under the given load. The pin can be of any shape,
however, the most popular shapes are spherical (ball or
lens) or cylindrical due to ease of alignment of such pins
(flat pins are typically subject to certain misalignment which
can lead to non-uniform loading and difficulties for
theoretical analysis). During the test, the friction force, wear
and temperature are continuously monitored.
A typical friction curve measurement recorded on a pin on
disk apparatus is shown in the figure below:

BITS Pilani
Hyderabad Campus
THANKYOU

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