Advanced

Manufacturing
Choices
MAE 165-265
Spring 2013, Dr. Marc Madou
Class 2

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Table of Content
Manufacturing types: Primary, secondary and
tertiary manufacturing
Mechanical machining definition
Recognized categories of mechanical machining:
turning, milling, drilling and grinding.
CNC machining
Precision machining
Ultraprecision and nanotechnology
Desk top factory (DTF)
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Manufacturing Types
Manufacturing dominates world trade. It is the main wealth
creating activity of all industrialized nations and many developing
nations. A manufacturing industry based on advanced technologies
with the capability of competing in world markets can ensure a
higher standard of living for an industrial nation (McKeown, 1996).
Where primary manufacturing processes involve casting* and
molding**, secondary manufacturing processes constitute the main
mechanical removing techniques involving turning, drilling and
milling. Abrasive processes to super-finish a work-piece are called
tertiary manufacturing processes. Casting*/molding**: The act or process of
making casts or impressions, or of shaping metal or plaster in a mold; the act or the
process of pouring molten metal into a mold.

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Manufacturing Types
The difference between casting
and molding is that in "traditional"
casting processes, the mold is
destroyed/ consumed when
removing the work-piece from it
while in molding, the mold is reused multiple times(this difference
is not often respected in naming
different processes).
Lost wax casting process: see video
Sand casting: see utube:
http://youtu.be/rgL2Jn5mk1A

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Mechanical Machining
In mechanical removal processes, stresses induced by
a tool overcome the strength of the material.
The process produces complex 3D shapes, with very
good dimensional control, and good surface finishes.
The method is wasteful of material, and expensive in
terms of labor and capital.
How well a part made from a given material holds its
shape with time and stress is referred to as the
dimensional stability of the part and the material.
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Mechanical Machining
To maximize dimensional stability, the machine design
engineer tries to minimize the ratios of applied and residual
stress to yield strength of the material.
A good rule of thumb is to keep the static stress below 10 to
20% of yield strength.
Increased heat at the work-piece causes uneven dimensional
changes in the part being machined, making it difficult to
control its dimensional accuracy and tolerances. Thermal
errors are often the dominant type of error in a precision
machine, and thermal characteristics such as thermal
expansion coefficient and thermal conductivity deserve
special attention .

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Mechanical Machining
In mechanical subtractive machining, physical removal of
unwanted material is achieved by mechanical energy applied
at the work piece.
Mechanical material removing technologies are also
categorized as single point machining or abrasive machining
i.e., multi-point machining.
Mechanical removal processes can be broken down into four
commonly recognized categories: turning, milling, drilling and
grinding.

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First lathe as depicted in an Egyptian

bas relief; about 300 B.C. Shown here
in a line drawing. The man at left is
holding the cutting tool. The man at the
right is making the workpiece rotate back
and forth by pulling on a cord or thong.

Mechanical Energy Based Removing

What is milling? The use of a rotating multi-point cutting tool to
machine flat surfaces, slots, or internal recesses into a work-piece.
Milling is one of the more versatile machining processes. There are
three degrees of freedom associated with milling. The tool can move
up and down, left to right, and front to back. In this process the tool
spins while the part remains stationary. Although milling is a more
versatile process than turning or grinding, it is not as accurate and
tends to leave a rougher surface finish than the other two processes.
What is turning ? Turning is the machining operation that produces
cylindrical parts. In its basic form, it can be defined as the
machining of an external surface with the work-piece rotating and
with a single-point cutting tool.

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Mechanical Energy Based

Removing
The main difference between turning and milling is that in turning
the work-piece spins while the tool remains stationary. Because of
this, turning can be used to create a great surface finish on
cylindrical parts.
Turning is done on a machine called a lathe. The lathe spins the
workpiece, while the lathe operator can position the tool to remove
the material. The work-piece is held in the chucks of the lathe.

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Mechanical Energy Based Removing

Drilling can be defined as a rotary
end cutting tool having one or
more cutting lips, and having one
or more helical or straight flutes
for the passage of chips and the
admission of a cutting fluid.

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Mechanical Energy Based Removing

Grinding is a finishing process that is used to remove
surplus material from the work-piece surface. It is
usually used on almost any surface that has been
previously rough machined and is among the most
expensive process for it is generally quite slow in
removing material.

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Mechanical Energy Based Removing

By 1977, highly precise instruments such as
servomotors, feedback devices, and computers were
implemented, paving the way for computer
numerical control machining, commonly called CNC
machining, which is now standard in many types of
machine shops. At the start, the smallest movement
these machines could reproducibly make was 0.5
m.
The resolution of the steps a machine can make, of
course, is a determining factor for the manufacturing
accuracy of the work-piece.
Numerical control is a method of automatically
operating a manufacturing machine based on a code
of letters, numbers, and special characters.

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Mechanical Energy Based Removing

Point-to-point control systems cause the tool to move
to a point on the part and execute an operation at
that point only. The tool is not in continuous contact
with the part while it is moving.
Continuous-path controllers cause the tool to
maintain continuous contact with the part as the tool
cuts a contour shape.

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Mechanical Energy Based Removing

These continuous
operations include
milling along any lines
at any angle, milling
arcs and lathe turning.

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Mechanical Energy Based Removing

CNC milling machines
can perform
simultaneous linear
motion along the three
axis and are called
three-axes machines.
More complex CNC
machines have the
capability of executing
additional rotary motions
(4th and 5th axes).
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Right

Vertical
milling
machine
hand
rule

Mechanical Energy Based Removing

Machining Centers, equipped with automatic tool changers,
are capable of changing 90 or more tools. Can perform
milling, drilling,boring* turning, on many faces. * Boring is

the process of using a single-point tool to enlarge a preexisting hole.

Process flow:

Develop or obtain the 3D geometric model of the part, using

CAD.
Decide which machining operations and cutter-path directions
are required (computer assisted).
Choose the tooling required (computer assisted).
Run CAM software to generate the CNC part program.
Verify and edit program.
Download the part program to the appropriate machine.
Verify the program on the actual machine and edit if
necessary.Run the program and produce the part.

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Mechanical Energy Based Removing

In an integrated CAD/CAM
system, the geometry and
tool motions are derived
automatically from the CAD
database by the NC program
(Pro/E, Unigraphics, .)

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CNC milling is a cutting process in which material is removed

from a block of material by a rotating tool using a computer
numerically controlled program or code to achieve a desired
tool path to machine very accurate parts precisely and efficiently.

Precision Machining
Mechanical engineers define precision machining as machining in
which the relative accuracy (tolerance/object size) is 104 or less of a
feature/part size
For comparison, a relative accuracy of 103 in the construction of a
house is considered excellent. It is important to realize that, while IC
techniques and silicon micro- and nano-machining can achieve
excellent absolute tolerances, relative tolerances here are rather
poor compared to those achieved by most mechanical machining
techniques.
The decrease in manufacturing accuracy with decreasing size is
rarely mentioned in discussions of Si micro-machines; this probably is
because Si micromachining originated from electrical engineering
practice rather than mechanical engineering.
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Precision Machining
In the 1980s advanced machine tools became equipped with
precision metrology and control tools. These machines used
laser interferometer and capacitance probe feedback
controls, temperature control and hydrostatic bearings, and
featured accuracies better than 0.1 micrometers. Precision
manufacturing methods were extended for industrial use for
cutting aluminum, which was used for making components for
scanners, photocopying machines and computer memory disks.
Also in the 1980s, cutting with very small diamond tools (e.g.,
22 m diameter) was developed in Japan.
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Ultra Precision MachiningNanotechnology

Taniguchi coined the term
nanotechnology and in 1974, used the
term to define ultra-precision
machining.
Taniguchi defines ultra-precision
machining as the process by which
the highest possible dimensional
accuracy is achieved at a given point
in time.
Norio Taniguchi predicted accuracies
along with the processes or tools used
to achieve it (next page)

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Norio Taniguchi ( ) (27 May 1912 - 15 November 1999)

was a professor of Tokyo Science University.

Precision and ultra-precision machining

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Ultra Precision MachiningNanotechnology

By 1993, 0.05 m became possible, and
today there is equipment available
featuring 0.01 m and even nanometer
step resolution 10
(http://www.fanuc.co.jp/eindex.htm).
This evolution closely follows the
predictions sketched in the Taniguchi
curves showing a machining accuracy for
ultra-precision machining of subnanometer resolution for the year 2008
(see previous slide) .
Fanucs the ROBOnano Ui an ultra-precision
micromachining station (cost 1 $ million)
and a Noh mask made with this machine (
http://www.fanuc.co.jp/en/product/robo
nano/index.htm
).

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Desk top factory

The fact that it often takes
a two-ton machine tool to
fabricate micro parts,
where cutting forces are in
the milli- to micro-Newton
range is a clear indication
that a complete machine
tool redesign is required for
the fabrication of micromachines.
One approach is the desktop factory.
Commercial desktop factories (DTFs) at Sankyo Seiki.

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Desk top factory

Desktop factories (DTF) constitute a rather interesting new manufacturing
philosophy involving flexible and modular table-top-sized automated
factories that feature minimal human participation in the manufacturing
process.
An example of such a factory is shown below. Since the early nineties
progress has been made towards making such desktop factories (DTF) a
reality. A desktop factory as shown here has the potential of becoming the
factory of the future: a totally self-contained, robotic, desktop-size
machine tool that only requires materials, power and water as outside
inputs, and out come the finished machined products. The first R&D
desktop factories incorporated lathes, cleaning, gluing, punching and
drilling stations. The workpiece is transported between these different
machining functions by a cart moving from station to station.

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Desk top factory

An example of a
desktop factory at
AIST, Japan.

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