Introduction to Manufacturing

Technology
(Overview of Manufacturing technologies)

Instructors:
(1)Shantanu Bhattacharya, ME, IITK, email:
bhattacs@iitk.ac.in
(2)Prof. Supratik Mukherjee, ME, IITK email:
smukh@iitk.ac.in
 Overview of the Lecture

• Manufacturing systems approaches.

• Basic manufacturing processes. (Casting, Forming process,
Fabrication process, Material removal process)
• Advanced Machining processes (ECM, EDM, EBM, LBM, AJM,
USM processes)
• Micro-manufacturing processes (Etching, Deposition,
Lithography, Replication and molding, Dip-pen lithography,
Compression molding, Nano-imprint lithography)
 Manufacturing Systems Approach
Definition of Manufacturing Technology:

•Manufacturing technology provides the tools that enable production of all

manufactured goods. These master tools of industry magnify the effort of
individual workers and give an industrial nation the power to turn raw materials
into the affordable, quality goods essential to today’s society.
•Manufacturing technology provides the productive tools that power a growing,
stable economy and a rising standard of living. Thus manufacturing process really
represents adding value to a raw material and creation of wealth.
Replenish

Sales Production rate,

fluctuations quality and
Manufacturing delivery
Raw materials cost and
Manufacturing availability System
Business Profit
Facility Add environment
comprising of
Value Social Pressure manufacturing Reputation
Output Input processes
Resources and
plans

Wealth Manufacturing
Process is the key
to wealth
generation
 Casting Processes
• These are the only processes where
liquid metal in used.
• Casting is the oldest known
manufacturing process.
• It requires preparation of a cavity usually
in a refractory material to resemble
closely to the object to be realized.
• Molten metal is poured into this
refractory mould cavity and is allowed to
solidify.
• The object after solidification is removed
from the mould.
 Forming Processes
• These are solid state manufacturing processes involving minimum amount of
material wastage and faster production.
• Metal is heated to a temperature which is slightly below the solidus temperature
and then a large force is applied such that the material flows and take the desired
shape.
• The desired shape is controlled by means of certain tools called dies which may be
completely or partially closed during manufacture.
• These processes are normally used for large scale production rates.

Extrusion
Drop forging

Rolling Process

Wire Drawing
 Fabrication processes
• These are secondary manufacturing processes where the starting raw
materials are processed by any of the previous methods.
•It essentially involves joining pieces either temporarily or permanently so
that they would perform the necessary function.
•The joining can be achieved by both heat and pressure and / or a joining
material.
Gas Welding
Resistance Welding

Arc Welding
 Material Removal Processes
• These are also secondary manufacturing processes where the additional unwanted
material is removed in the form of chips from the blank material by a harder tool
so that a final desired shape can be obtained.
• Material removal is the most expensive manufacturing process because more
energy is consumed, and also a lot of waste material is generated in the process.

Turning Shaping
Grinding

Milling Drilling
Sawing
 History of Machining
• Mankind used bones, sticks and stones as
hand tools since the earliest times

The most ancient Paleolithic stone tool During the Upper Paleolithic further
industry the Oldowan was developed by technological advances were made such
the earliest members of the genus Homo as the invention of Nets, bolas, the spear
such as Homo habilis around 2.6 million thrower the bow and arrow.
years ago. and contained tools such as
choppers, burins and awls.
 History of Machining
Hand held tools from Bronze Age
developed around 1 million years back.

Upto almost the seventeenth century all

tools were either hand operated or done
so by other very elementary methods.

Introduction of water, steam and later

electricity as useful sources of energy
led to the concept of power driven Ceremonial giant dirk of the
machine tools. Plougrescant-Ommerschans type, Bronze Age weaponry
Plougrescant, France, 1500-1300BC. and ornaments

John Wilkinson in 1774 first constructed a precision

machine for boring engine cylinders, powered by steam.
 History of Machining

• 23 years later, Henry Maudslay made a further advancement in machining

when he devised screw cutting engine lathes.
• James Nasmyth invented the second basic machining tool for shaping and
planing.
First Universal Milling machine was built by J.R. Brown in
1862.

In the late nineteenth century, the grinding machine was

introduced. An advanced form of this process is the lapping
process used to produce a high quality surface finish and a
very tight tolerance
 History of Machining

• In the later part of 19th and 20th Centuries the machine tools became
increasingly electrically powered.
• The basic machine tools had further refinements; for instance multiple
point cutters for milling machines were introduced.
• The whole machining paradigm was however still related to an operators
judgment who by looking at a part and using his skills would set up an
operation sequence and use this for machining the work piece. Accuracy
of such a product would depend solely on the operator.
• The introduction of NC (numerical control) in 1953 lead to computer
numeric control and direct numeric control.
• Present capabilities of these tooling systems have enormously increased
due to development in electronic controls and computers and present
capabilities enable complex shapes to be produced with finishing accuracy
close to a + 1 Micron.
 History of Machining
• In modern machining practices, harder, stronger, and
tougher materials that are more difficult to cut are used. So,
processes should be independent of material properties of
the work piece.
• Non conventional machining practices came very handy as
an alternative to the conventional domain which could
handle shape complexity, surface integrity and
miniaturization requirements.
• Hybrid machining made use of the combined enhanced
advantages of two or more participating processes.
• Micromachining had emerged because of this change of
capabilities.
• Recent applications of micromachining include silicon/ glass
micromachining, excimer lasers and photolithography.
 History of Machining
• Machines such as precision grinders may be capable of
producing an accuracy level of + 1 microns that can be
measured using laser instruments and optical fibers.
• Future trends in micromachining include laser and electron
beam lithography and super high precision grinding, lapping
and polishing machines. For measurements high precision
laser beam based scanners are used for measuring surface
finish etc.
• Nano-machining is a very recent trend in these processes
wherein atoms and molecules can be removed instead of
chips in conventional machines.
• Nano-machining was introduced by Tanigushi to cover the
miniaturization of components and tolerances in the range
from submicron level to that of an individual atom or
molecule between 100nm and 0.1 nm.
 Machining Accuracies
100 -1 microns

1 -0.01 microns

Micro-turning and Micro-Milling M/C

0.1 -0.001 microns

Classification of all Material Removal
Processes
 Non Traditional Machining
• Traditional machining is mostly based on removal of materials
using tools that are harder than the materials themselves.
• New and novel materials because of their greatly improved
chemical, mechanical and thermal properties are sometimes
impossible to machine using traditional machining processes.
• Traditional machining methods are often ineffective in
machining hard materials like ceramics and composites or
machining under very tight tolerances as in micromachined
components.
• New processes and methods play a considerable role in
machining for aircraft manufacture, automobile industry, tool
and die industry mold making etc.
• They are classified under the domain of non traditional
processes.
 Classification of Non Traditional Machining

Single action non traditional Machining processes:

For these processes only one machining action is used for material removal. These
can be classified according to the source of energy used to generate such a
machining action: mechanical, thermal, chemical and electrochemical.
 Mechanical Machining
• Ultrasonic Machining (USM) and Waterjet Machining (WJM) are typical examples of
single action, mechanical non traditional machining processes.
• The machining medium is solid grains suspended in an abrasive slurry in the
former, while a fluid is employed in the WJM process.
• The introduction of abrasives to the fluid jet enhances the machining efficiency and
is known as abrasive water jet machining. Similar case happens when ice particles
are introduced as in Ice Jet Machining.
Introduction to Abrasive Jet Machining
(AJM)
• In AJM, the material removal takes place due
to impingement of the fine abrasive particles.
• The abrasive particles are typically of
0.025mm diameter and the air discharges at a
pressure of several atmosphere.
 Mechanics of AJM
• Abrasive particle impinges on the work
surface at a high velocity and this impact
causes a tiny brittle fracture and the following
air or gas carries away the dislodged small
work piece particle.
Thermal Machining
• Thermal machining removes
the machining allowance by
melting or vaporizing the
work piece material.
• Many secondary phenomena
occur during machining such
as microcracking, formation
of heat affected zones,
striations etc.
• The source of heat could be
plasma as during EDM and
PBM or photons as during
LBM, electrons in EBM, ions
in IBM etc.
 Electric Discharge Machining
• EDM is the process of material removal by a controlled erosion
through a series of electric sparks.
• It was developed in USSR around 1943.
• The basic process is illustrated below.
• When a discharge takes place between two points of the anode
and cathode the intense heat generated near the zone melts
and evaporates the materials in the sparking zone.
• For improving the effectiveness the work-piece and the tool are
submerged in a dielectric fluid. (Mineral oils or hydrocarbons)

•Experiments indicate that in

case both electrodes are of
the same material there is
prominently more erosion of
the electrode connected to
the positive terminal.
Chemical and Electrochemical
Machining
• Chemical milling and
photochemical machining or
photochemical blanking all use a
chemical dissolution action to
remove the machining allowance
through ions in an etchant.
• Electrochemical machining uses
the electrochemical dissolution
phase to remove the machining
allowance using ion transfer in an
electrolytic cell.
 Electrochemical Machining (ECM)
•Electrochemical machining is one of the most unconventional machining
processes.
•The process is actually the reverse of electroplating with some modifications.
•It is based on the principle of electrolysis.
•In a metal, electricity is conducted by free electrons but in a solution the
conduction of electricity is achieved through the movement of ions.
•Thus the flow of current through an electrolyte is always accompanied by the
movement of matter.
•In the ECM process the work-piece is connected to a positive electrode and the
tool to the negative terminal for metal removal.
•The figure below shows a suitable work-piece and a suitably shaped tool, the gap
between the tool and the work being full of a suitable electrolyte.
 Introduction to MEMS fabrication
NEMS/ MEMS silicon fabrication
•Formation of structures that could be used to form
sensors and actuators.
•Processing of electrical or non electrical signals.
•Conventional and new semiconductor manufacturing
techniques are used.
•Etching, Deposition, Photolithography, Oxidation,
Epitaxy etc.
•Deep RIE, Thick plating etc.
Bulk and surface micromachining.
 Topics Covered
• Introduction to manufacturing processes and system concept and its evolution;
Manufacturing properties of materials [4 Lectures] [SB]
• Metal casting: Solidification Mechanism, Gating and Riser Design, Defects and Product
Design; [ 8 Lectures] [SB]
• Unconventional Material Removal Processes: Jet Machining, ECM, EDM, EMB and LBM;
Rapid Prototyping and Tooling; Microfabrication technologies; [8 Lectures][SB]
• Metrology and Selection of Manufacturing Processes. [2 Lectures] [SB]
• Metal Forming: Fundamentals of Plasticity, Force Equilibrium Method, Forging/upsetting,
Drawing, Extrusion, Deep Drawing and Bending, Defects; [8 Lectures] [SM]
• Machining: Tool Specifications, Orthogonal and Oblique cutting, Tool wear and Tool Life,
Economics of Machining; Shaping processes for Plastics and Tool Design; [7 Lectures] [SM]
• Joining Processes; Classification of Joining processes, Principles of Fusion (Liquid State),
Principles of Solid/liquid state joining, Various joining processes, Weld defects and inspection
[3 lectures] [SM]
References/Text Books: 1. Ghosh, A., Mallik, A.K., Manufacturing Science (2nd edition}, EastWest Press, 2010.
2. Lal, G.K., Introduction to Machining Science (2nd edition}, New Age Internationalpublishers, 2009.
3. Groover, M.P, Fundamentals of Modern Manufacturing (2nd edition}, john Wiley.
4. Kalpakjian, S., Schmid, S.C., Manufacturing Engineering and Technology, PearsonEducation
5. Galyer, j.F.W., Shotbolt, C.R., Metrology for Engineers, ELBS
 Laboratory Requirement
• (1) Oblique cutting, cutting force coefficient identification [SM]
• (2) EDM: To study the EDM machine and the relevant measuring systems/
To determine material removal rate (MRR) and tool wear rate (TWR)
during machining of EN8 steel/ To measure the initial and final out of
roundness of the copper tool. [SB]
• (3)Deep drawing through Hydraulic press. [SM]
• (4) Mechanistic identification of cutting force coefficient in milling. [SM]
• (5) 3-D printing + metrology [SB]
 General Instructions for Lab users
• (1) Every student must see the videos of the individual experiments being posted
by the instructors
• (2) All students must thoroughly read through the users manual that will be sent
separately online.
• (3) Data will be sent to all students out of which each have to individually calulate
the various required parameters and fill up the lab report/ post it in the link that
will be sent by instructors.
• (4) The students should be prepared for a lab quiz and also another round of
evaluation which will be planned later by the instructors and intimated
accordingly.
 Course Requirements
• (1) 40% of total grade upto Mid Semester
• (2) 40% of total grade upto Final Examination
• (3) 20% of total grade on Experiments.
(The rationale of the distribution of marks upto the first mid sem is
the following.)
• There will be four assignments in each areas taught by SB upto
mid-sem.
• All coming upto mid-sem will not be reflected in final exam.
• There will be a mid-semester examination
• The modalities of final examination will be shared by SM after
mid-sem exam.