Nontraditional Manufacturing Processes: MF30604

A K Nath Lecture No.-1 Introduction to NTMPs

Fabrication of large size domes Fabrication of

Micro-lens

60m square hole in Si

Curved slot in SS

Conventional Machining Processes (Material Removal): Primarily rely on electrical motors and hard tool materials to perform tasks e.g. Turning, Drilling, Boring, Milling, Shaping, Sawing, Slotting, & Grinding etc.

Main Characteristics of Conventional Machining: * Material removal by chip formation * Material removal by mechanical force * Cutting tool harder than work piece under machining condition * Direct mechanical contact - residual mechanical & thermal stress.

Need of Modern Manufacturing Processes !

Challenges & Competition in Manufacturing Industries: New Products - Better Performance, More Features, More Durable, Less Production Time, Energy Efficient, Low cost, Demand for Products with New exotic work materials: Improved mechanical, thermal, & chemical properties Super alloys, ceramics and composites * Too hard / brittle to machine with traditional process * Materials too flexible / slender to cut or clamp Ex: Machining Polycrystalline diamond - fast wear of grinding wheel; Quartz Silicon wafer, Ceramic Damage during machining Innovative designs, complex shapes, high precision & high surface quality * Stringent design requirements * Micro- Nano Sizes

Micro-lenses 60m square hole in Si Curved slot in SS

Other requirements of the New Manufacturing Process Low machining cost * Automated processing, Fast production Rapid change of Product design * Elimination of Traditional tooling to reduce time & cost Less Temperature rise or residual stresses

Photochemical Machining

Electro-Discharge Machining

Modern / Nontraditional Manufacturing processes employing

New tools and New forms of energy Developed as Efficient and economic alternatives to conventional ones Often the first choice for certain technical requirements. Modern / Nontraditional Manufacturing Processes differ to Traditional Mfg. Processes in following aspects Unconventional Energy Sources : Thermal, Chemical, Kinetic Energy --- Processing usually not by direct MECHANICAL contact: Nontraditional mechanism of interaction between the tool and work piece: Evaporation, Ablation, Melt Ejection, Dissolution, Erosion--- Nontraditional media to transfer energy from the tool to the work piece : Photons, E-beam, Dielectric media, Electrolytic media, Water, Abrasive slurry.

Basic NTM Process Groups:

* Thermal NTM Processes
- Laser Beam Machining (LBM) - Electron Beam Machining (EBM) - Plasma Arc Machining (PAC) - Electrical Discharge Machining (EDM)

* Mechanical NTM Processes( Plastic deformation / Abrasive Erosion) - Abrasive Jet Machining (AJM)
- Ultrasonic Machining (USM) - Water Jet Machining (WJM) - Abrasive Water Jet Machining (AWJM)

* Electrochemical NTM Processes

- Electrochemical Machining (ECM) - Electrochemical Grinding (ECG)

* Chemical NTM Processes

- Chemical Machining (CHM) - Thermo chemical Machining (TCM)

* Kinetic Energy ( Atom by atom knocking)

- Ion beam

Characteristics of Modern / Non Traditional Machining (NTM) Processes: Mostly NTM processes do not use mechanical energy for material removal. They use different forms of energy for machining. Example, USM, AJM, WJM - Mechanical energy ECM- Electrochemical dissolution Laser, EDM, EB - Thermal Material removal with chip formation or even without chip formation Example: AJM - Microscopic size chips ECM - Electrochemical dissolution at atomic level In NTM, Physical tool may or may not be present. Example: Laser beam machining- No tool, Electrochemical Machining- Physical tool needed In NTM, Tool need not be harder than the work piece material. Example: EDM, copper tool to machine hardened steels. Nontraditional media for energy transfer: EDM: Dielectric fluid, Laser: Coherent photon beam

Attributes of Nontraditional Machining Processes:

Increased Productivity: Faster operation Reduction in the number of overall operations; Reduced Rejection: Improved repeatability Reduction in in-process breakage of fragile work piece.

Perform operation not feasible by traditional Manufacturing Processes, Example drilling holes of very high depth to width aspect ratio, 100:1 Easy automation, On-line Process Monitoring & Control: Increased reliability, repeatability; reduced human involvement Versatile & Virtually unlimited Capability: Ex.- Laser can cut most materials of any hardness: diamond, metals, concrete, glass, plastics, textiles, wood etc. Drill holes of any diameter

Course Outline by Topical Areas: Introduction to Nontraditional Manufacturing Processes Thermal Processing: Laser Beam Machining (LBM): Fundamentals of Materials Processing- (Laser cutting, drilling, welding, surface modification- hardening, alloying, cladding; marking, micro-machining, laser rapid prototyping & manufacturing) Equipment for Laser Beam Processing Electron Beam Machining (EBM) Fundamentals of Materials Processing (Ebeam machining, welding, lithography) Plasma Arc Machining (PAM): Cutting, Welding & Plasma Spraying Ion-Beam Machining (IBM): Ion Beam removal, deposition, surface treatment Mechanical NTM Processes( Plastic deformation / Abrasive Erosion) - Abrasive Jet Machining (AJM) - Ultrasonic Machining (USM) - Water Jet Machining (WJM) - Abrasive Water Jet Machining (AWJM)

Objective of this course:

Learn about the basic theory, working principle, and characteristics of different nontraditional manufacturing processes. Identify critical process variables and their effect on process performance and product quality Develop mathematical model relating MRR with machining parameters Develop understanding to properly assess the capabilities, limitations, and potentials of nontraditional manufacturing processes

Examples where NTM processes is the first choice

Intricate shaped blind holes- e.g. square holes of say 10x10mm with a depth of 20mm EDM / ECM Machining hard materials- e.g. Diamond, Inconel, Ti-Alloys, Composites, Ceramics or Carbides EDM, ECM, LBM Small diameter holes with large aspect ratio (0.5mm , 10mm l)

LBM, EBM, EDM

Flexible , Brittle materials WJ, AWJ, EDM, PCM, LBM, EBM

Abrasive Machining

Laser Cutting

Course Materials : Lecture Notes Reference Books : 1. Nontraditional Manufacturing Processes Gary F. Benedict, Marcel Dekker,Inc 2. Modern Machining Processes P C Pandey & H S Shan, Tata McGraw-Hill 3. Nonconventional Machining P K Mishra, Narosa Publishing House 4. Manufacturing Science Amitabha Ghosh & A K Mallik, Affiliated East-West Press 5. www.nptel.iitm.ac.in National Programme on Technology Enhanced Learning (NPTEL) Course- IIT Kharagpur- Manufacturing-Module 9 (on NTM) Lessons 35-40. 6. Laser Material Processing, by W M Steen