Advanced Manufacturing Technologies

Manufacturing: The term manufacturing refers to the processing of raw materials or parts into finished
goods through the use of tools, human labor, machinery, and chemical processing. Manufacturing allows
businesses to sell finished products at a higher cost than the value of the raw materials used. Large-scale
manufacturing allows for goods to be mass-produced using assembly line processes and advanced
technologies as core assets. Efficient manufacturing techniques enable manufacturers to take advantage of
economies of scale, producing more units at a lower cost.
The following is an example of a flowchart, based around a manufacturing process, with components being
received into an incoming inspection point. Inspections are performed and the components are either deemed
acceptable or un-acceptable. The components then progress into production and are subject to a final test. If
acceptable are dispatched to the customer. Throughout the process data is recorded. At the incoming
inspection point, some parts may be rejected and need to get returned back to a supplier. Also during the
process, instructions will be received in the form of inputs into the process i.e. “request from Production”.
Understanding Manufacturing
Manufacturing is an integral and huge part of the economy. It involves the processing and refinement of raw
materials, such as ore, wood, and foodstuffs, into finished products, such as metal goods, furniture, and
processed foods. Converting these raw materials into something more useful adds value. This added value
increases the price of finished products, making manufacturing a very profitable part of the business chain.
Some people specialize in the skills required to manufacture goods, while others provide the funds that
businesses need to purchase the tools and materials.
Modern manufacturing: is to a large extent based on deformation processing. This applies in particular to
elastic–plastic matter such as metallic alloys, composites, and polymers. Understanding of these materials
and more advanced deformation processing techniques are paramount to modern manufacturing and product
development. The current state in this field is characterized by the close integration of engineering concepts
pertaining to manufacturing technology and materials physics on the one hand, and by the close integration of
experiment, industrial processing, and computer simulation on the other.
Deformation processing encompasses such different techniques as forging, rolling, extrusion, drawing, or
bending. Modern understanding of these techniques consists not only in attaining mere shape changes of
plastic matter but also in optimizing their microstructures and properties.
Need of Advanced Manufacturing Technologies: Advanced-manufacturing technologies can boost
innovation by allowing manufacturers to create new kinds of products that can’t be made cost effectively
with conventional processes. They also permit manufacturers to produce high-quality goods made to buyers’
exact specifications.
 Manufacturing is the basis for all economic activities and future growth of a country

 At the beginning of 20th century, mass production using efficient machine tools emerged in USA (Ford
motors)

 After the second world war, new / advanced manufacturing processes came into existence

 Since 1950s, new technologies have been emerged – computerized numerical control, flexible
manufacturing systems, lean manufacturing, green manufacturing, computer integrated manufacturing are
some of those.

 Newer materials have been developed and their processing requires special machine tools or special
manufacturing process

 Therefore, there is a vital need to have more efforts to continuously advance manufacturing technology for
a better-off and more stable future.

Manufacturing processes classification

There are six basic / fundamental classifications of manufacturing processes.
1. Metal casting or Molding: expendable mold and permanent mold

2. Metal Forming and Shearing: rolling, forging, extrusion, drawing, sheet forming, powder metallurgy

3. Material Removal Processes / Machining Processes: turning, boring, drilling, milling, planning, shaping,
broaching, grinding, ultrasonic machining, chemical machining, electrical discharge machining (EDM),
Abrasive flow machining (AFM), abrasive jet
machining (AJM), electrochemical machining, high-energy beam machining, laser beam machining (LBM)
etc.
4. Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding, mechanical joining, plasma arc,
plasma MIG, projection welding, ultrasonic, electron beam welding, laser welding etc.
5. Finishing (painting, anti-corrosion coatings, etc.)
6. Rapid Manufacturing: stereo-lithography, selective laser sintering, fused deposition modeling, three
dimensional printing, laminated object manufacturing, laser engineered net shaping

Features of Advanced manufacturing Techniques:

 Efficient Production. ...
 Intelligent Production. ...
 Effective Organization. ...
 Additive Manufacturing. ...
 Advanced and Composite Materials. ...
 Robotics and Automation. ...
 Laser Machining and Welding. ...
 Nanotechnology.

Advancement in material technology leading to advancement in Manufacturing Process

(Five Technological Applications Impacting Manufacturing Innovation:)
1. Additive Manufacturing / 3D Printing
Additive manufacturing was actually developed in the 1980’s, but has picked up more significant interest in
the last few years. It covers any and all processes involved in printing a 3-dimensional product, the reason it’s
commonly referred to as 3D printing. Additive manufacturing includes a technique called cold spraying,
which involves blasting metallic particles through a nozzle at high speeds, binding particles together to form
shapes. This creates a part by building materials layer by layer through the control of a computer. Because the
end result is a high precision replica of an original design, there is less waste during the production process
and can save the manufacturer money.
Historically, additive manufacturing technology has been expensive and was typically used by the “bigger
fish” in the field. However, recent advancements have enabled additive manufacturing to become more
affordable, and it is anticipated to become a common option for smaller manufacturers. 3-D printers will
continue to change the manufacturing landscape by creating more efficient ways to manufacture custom parts
and goods.
2. Advanced Materials A report from the President’s Council of Advisors on Science and Technology
(PCAST) notes that “almost all the megatrends for the future — energy efficiency or alternate energy
devices, new materials to counter resource shortages, next-generation consumer devices, and new paradigms
in chemical safety and security — depend heavily on advanced materials” and that these advanced materials
“will fuel emerging multi-billion dollar industries.” This includes advanced composites, which have to date
been largely restricted to use in a limited number of high-cost applications. However, efforts are underway to
develop manufacturing processes that lower cost and speed production such that advanced composites are
integrated into a much wider range of products and applications in the coming years.
3. Cloud Computing
Cloud based computing uses network connected remote services to manage and process data. Life in the
cloud will gain momentum, but security concerns must be continually addressed. Companies are increasing
use of this technology across various geographic locations to share data to make better business decisions.
Cloud Computing helps reduces costs, improve quality control and shorten production times.
4. Internet of Things (IoT): Many of us now can’t imagine life before the smartphone…welcome to the idea
of a smart manufacturing facility. Smart technology is not brand new, but it is steadily developing into the
wave of the future for manufacturing.
Imagine a workplace where connected equipment will be able to communicate via the Internet and
computerized manufacturing machinery will be able to “talk to each other” and send/receive notifications
about operating conditions. Once a problem is detected, a notification is sent to other networked devices so
the entire process can be automatically adjusted. The end result will be reduced downtime, improved quality,
less waste and lower costs. This technology will lead to the development of new types of positions for the
manufacturing workforce.
5. Nanotechnology
Nanotechnology deals with matter between 1 and 100 nanometers; a nanometer is one-billionth of a meter.
Nanotechnology was traditionally used in the aerospace and biomedical arenas, but is now being used to
manufacture lightweight stronger materials for boats, sporting equipment and auto parts, as well as being
used in creating personal care items such as eyeglasses.
Nanostructure catalysts make chemical manufacturing processes more efficient by saving energy, reducing
waste and will also have increased applications in healthcare and pharmaceuticals.
Materials used in High Temperature applications:
1. TITANIUM
Titanium is a lustrous transition metal which is silver in colour.Titanium alloys have high tensile strength to
weight ratio, good toughness, extraordinary resistance to corrosion and an ability to withstand extreme
temperatures of 600°C plus. It is readily weldable and possesses good fabricability and effectiveness in many
challenging industrial applications.
2. TUNGSTEN
Tungsten is a steel-grey or silver-white refractory metal. Tungsten can be used as the base metal for an alloy
or as a supporting element. Tungsten provides high hardness levels, a high resistance to heat and a high
melting point. Tungsten is commonly used in Combustion liners, Turbine exhaust components, Aircraft cabin
heaters, Transition Ducts & Industrial furnaces.
3. STAINLESS STEEL
Stainless steel is an iron base alloy with a minimum of 10.5% or more of chromium as well as other metals
like molybdenum and nickel. Stainless steel alloys are known for their resistance to corrosion and heat, which
makes them ideal for use in the Aerospace, Automotive and Construction industries as well as specific parts
like Pressure Vessels, Steam Turbines, Boilers and Piping systems.
4. MOLYBDENUM
Molybdenum is a refractory metallic element that forms hard, stable carbides that enhance hardenability,
strength, toughness and resistance to wear and corrosion. Molybdenum is frequently used in high-temperature
alloys in steel, cast iron and super-alloys in the Military and Defence Industry, Semiconductor and Speciality
Machine shops.
5. NICKEL
Nickel is a naturally occurring silvery-white lustrous metal with a gold tinge. It is malleable, ductile and has
superior strength and corrosion resistance. Nickel is frequently used in stainless steel and other alloys to make
them stronger. Nickel alloys are used in Gas Turbines, Power Generation, Aerospace, Speciality Engineering
and Electronics.
6. TANTALUM
Tantalum is a shiny, silvery metal that is soft when pure. It is virtually resistant to corrosion due to an
oxidised film on its surface. Tantalum is particularly useful in high-temperature applications in Aircraft
Engines as well as Electronic Devices..
Materials used in Automobile industry:
1. Steel
The manufacture of steel has improved a great deal. Different parts and areas of a car need different types of
steel. Steel is the main materials in manufacturing door panels, the chassis of the car, and the support beams.
It is also used in exhaust pipes and mufflers in the car.
However, it is mostly used on the frame of the car because of its strength. This means that it has a better
ability to absorb impact. The average car contains 2400 pounds of steel while and SUV has 3000 pounds of
steel.
Therefore, they help you remain safe on the road since it is a metal that is responsible for the heavyweight
and support of the cars.
2. Plastic
Plastics used in car manufacturing are petroleum by-products (gas and oil). Plastics are challengers to steel
because of their prominence in car manufacturing. They are malleable and still strong enough to hold the
structure in shape.
Plastics constitute almost half of the total car parts, being the main component in manufacturing the
dashboard, door handles, pipes, and air vents. The durability, versatility, and lightweight characteristics of
plastics make them the ideal materials for different parts.
3. Aluminum
Among other metals, the light-weight and durability of Aluminum make it perfect for specific car parts. It is
also malleable, making it a common material in car production. In 1970, it only accounted for 2% of the total
components of a car; today, it makes up to 15% of the total car parts.
The wheels, which are essential parts, are made of aluminum, replacing steel. Most engine blocks are also
made of steel even. Though it is not quite as durable as iron, it is lighter, and this boosts performance.
4. Rubber
Rubber produces engine mounts, hoses seals wiper blades, and belts. Like plastic, rubber is also cheap,
durable, and flexible.
Therefore, it can function in a wide array of parts, and it will also handle heat well in case the car heats up.
What most people do not know is that a large percentage of the rubber produced makes automobile parts.
5. Glass
Currently, glass is used in navigation screens, back-up camera lenses, and mirrors in your car. It helps the
driver have a clearer view of what they are doing and where they are going.
The windshields are made of laminated glass. Glass lamination assures users of the highest safety levels,
especially in the event of a crash.
Lamination involves putting a thin layer of vinyl between two glasses. This ensures that there is not shutter
when the glass is crushed.
6. Fiberglass
Most people think that glass and fiberglass are the same material. However, this is not true.
Fiberglass is made of small thin strands of glass. It is mostly air and not glass. When the glass is woven in
these small sheets and resin painted on it, smaller lighter things can be made.
Fiberglass offers a lot of benefits in the automotive industry. It is non-corrosive, so it helps replace steel in
areas where steel can get easily corroded.
Fiberglass is fireproof. In case of accidents, users can get out of the car uninjured. It can be used in front
bumpers, doors, roofs, casings, and the wheels.
7. Lead
Lead is an excellent metal because it is heavy and helps to balance the automobile. That is why most of the
wheels are made of lead, aluminum, and parts of fiberglass. The battery is also made of lead, which allows it
to maintain safe temperatures even when the car is heating up.
8. Copper
Copper is mostly used in wiring the car and any other electronic parts. The copper wires run throughout the
car in different systems like the radio, safety systems, and charging points. It is also found in starters.
9. Titanium
Titanium is an expensive metal. This is why most companies refrain from using it in their manufacturing
process since newer and cheaper methods of mining need to be developed. However, some companies use it
in metallic parts where steel and aluminum would traditionally be used. It mainly makes the cars look more
aesthetically pleasing.
10. Magnesium
The body, structure, and some engine parts are made of magnesium. It has been used in these parts since
1930. It is excellent because it is 75% lighter than steel and 33% lighter than aluminum. However, it is only
used in small areas so as not to throw off the balance of the vehicles.
Unconventional Machining Processes or Untraditional Machining Processes
Need and significance of Unconventional machining process:
1.High strength alloys: When the hardness of the work material is often higher than the cutting tool material
or when it becomes necessary to use the machining process on hardened material in such cases, the electro-
chemical processes described would be required.
2.Complex surfaces: when very complex surfaces in three dimensions need to be produced, such as those in
moulds and dies,where the workpiece surface being the hardened tool steel would be difficult to be processed
by the conventional means, the non traditional process would be required.
3.Higher accuracies and surface finish: The accuracy and surface finish desired in hard workpiece
materials require the conventional machining to be done very slowly as well as adding a number of finishing
processes, making the process very slow and uneconomical.
4.Difficult geometries: In addition to the complex geometries, sometimes it is required to produce difficult
geometries such as long holes with length to diameter ratio approaching that of 100, or very small size holes
such as those with less than 0.1mm in diameter which are almost impossible to be produced by conventional
methods.
5.Automation: The relative economic comparison of these processes.
Classification of Non- conventional Machining Processes :
Different types of energy are used in this machining process to remove metal.
Because of which on the basis of energy use
the unconventional machining process can be classified into four categories:
 Mechanical Energy Based
 Electrical Energy-Based
 Chemical and Electrochemical Energy Based
 Thermal Energy-Based

Mechanical Energy Based

In this process, mechanical energy is used to remove unwanted materials like abrasive jet machining, water
jet machining, ultrasonic machining, etc.
Electrical Energy-Based
In this process, an electrical spark is used to remove unwanted material like electrical discharge machining,
wire cut electrical discharge machining, etc.
Chemical and Electrochemical Energy Based
In this machining process, chemical energy is used to remove unwanted materials like photochemical
machining, electrochemical machining, electrochemical grinding, etc.
Thermal Energy-Based
In this machining, process heat is used to remove unwanted material like plasma beam machining, laser beam
machining, etc.
Types of Unconventional Machining Process
Some of the common types of unconventional machining processes are discussed which are used for
machining using different energy sources:
 Abrasive Jet Machining (AJM)
 Ultrasonic Machining (USM)
 Electrochemical Machining (ECM)
 Electrical Discharge Machining (EDM)
 Electron Beam Machining (EBM)
 Laser Beam Machining (LBM)
 Electrochemical Grinding ( ECG)