trends in advanced manufacturing

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A PAPER PRESENTATION ON “Trends in Advanced Manufacturing Processes” UNDER THE SVERI’S COLLEGE OF ENGINEERING, PANDHARPUR. Submitted By, Mr.Umesh M. Chikhale. Mr.Vaibhav R. Satpute. Mechanical Engineering (Third Year div-A) SVERI’s College of Engineering,Pandharpur 1

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Page 1: Trends in Advanced Manufacturing

A

PAPER PRESENTATION ON

“Trends in Advanced Manufacturing Processes”UNDER THE

SVERI’S COLLEGE OF ENGINEERING,

PANDHARPUR.

Submitted By,

Mr.Umesh M. Chikhale.

Mr.Vaibhav R. Satpute.

Mechanical Engineering (Third Year div-A)

Academic Year:-2016-2017

A) Introduction:-

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Over the past few decades, manufacturing has evolved from a more labor-intensive set of mechanical processes (traditional manufacturing) to a sophisticated set of information- technology –based processes (advanced manufacturing). Given these changes in advanced manufacturing, the National Intelligence Manager for Science and Technology in the Office of the Director of National Intelligence asked the Institute for Defense Analyses to identify emerging global trends in advanced manufacturing and to propose scenarios for advanced manufacturing 10 and 20 years in the future.The study team sought to answer the following questions:

What are converging trends in advanced manufacturing across technologyareas?

What are emerging trends in advanced manufacturing in specific technologyareas?

What are enabling factors that affect success in creating advancedmanufacturing products, processes, and enterprises?

i) Converging Trends:-The experts we consulted from academia, government, and industry identified five

large-scale trends that have been instrumental in the shift from traditional labor-intensive processes to advanced-technology-based processes. They are: (1) the ubiquitous role of information technology, (2) the reliance on modeling and simulation in the manufacturing process, (3) the acceleration of innovation in global supply-chain management, (4) themove toward rapid changeability of manufacturing in response to customer needs and external impediments, and (5) the acceptance and support of sustainable manufacturing.

ii) Emerging Trends:-Among the mature technology areas, two trends are emerging. First, because

semicondu- ctors are the cornerstone of the global information technology economy, multiple areas of research are underway, including the continued linear scaling of siliconbased integrated circuits, increased diversification of materials and approaches to building these circuits, and designing completely novel computing devices

iii) Enabling Factors:-The growth of advanced manufacturing within particular countries depends on factors that a country’s government can influence, such as infrastructure quality, labor skills, and a stable business environment, and factors that it cannot, such as trends in private-sector markets. The size of the market and growth potential are the primary reasons why companies choose to locate in a particular country or countries.

B) Defining Advanced Manufacturing:-

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Our definition of advanced manufacturing is intentionally broad in an attempt to capture all aspects of the topic. Our definition does not differentiate between traditional and high-technology sectors because new production processes and materials can also transform traditional industries such as the automotive sector.

Advances in science and technology and the convergence of these technologies are acritical building block of advanced manufacturing. The framework therefore highlights the role of breakthroughs in physics, chemistry, materials science, and biology, as well as the convergence of these disciplines, as the drivers for advanced manufacturing. Advances in computational modeling and prediction, in conjunction with exponential increases in computation power, also aid this effort. However, we do not assume that advances in manufacturing are solely driven by breakthroughs. Because substantive, incremental advances

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As the framework depicted in Figure 1illustrates, advanced manufacturinginvolves one or more of the followingelements:

Advanced products—Advancedproducts refer to technologically complexproducts, new materials, products withhighly sophisticated designs, and otherinnovative products (Zhou et al. 2009;Rahman 2008).

Advanced processes and technologies-- Advanced manufacturing may incorporate a new way of accomplishing the “how to” of production, where the focus is creating advanced processes and technologies.

Smart manufacturing and enterpriseconcepts—In recent years, manufacturing has been conceptualized as a system that goes beyond the factory floor, and paradigms of “manufacturing as an ecosystem” have emerged. The term “smart” encompasses enterprises that create and use data and information throughoutthe product life cycle with the goal of creating flexible manufacturing processes that respond rapidly to changes in demand at low cost to the firm without damage to the environment. The concept necessitates a life-cycle view, where products are designed for efficient production and recyclability.

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can lead to as much innovation in manufacturing as breakthrough advances, breakthrough innovation is not a prerequisite for change that improves the society and economy.

Figure 1. Advanced manufacturing is a multifaceted concept.

There is increasing convergence between manufacturing and services. With manufacturers integrating new “smart” service business models enabled through embedded software, wireless connectivity, and online services, there is now less of a distinction between the two sectors than before. Customers are demanding connected product “experiences” rather than just a product, and service companies such as Amazon have entered the realm of manufacturing (with its Kindle electronic reader).

Advanced processes and production technologies are often needed to produce advanced products and vice versa (Wang 2007). For example, “growing” an integrated circuit or a biomedical sensor requires advanced functionality and complexity, which requires new approaches to manufacturing at the micro scale and the nano scale.. Similarly, simulation tools can be used not only for making production processes more efficient, but also for addressing model life-cycle issues for green manufacturing.

Key framework conditions that set the stage for advances in manufacturing include government investments, availability of a high-performance workforce, intellectual property (IP) regimes (national patent systems), cultural factors, and regulations (Zhou et al. 2009; Kessler, Mittlestadt, and Russell 2007). Also critical to manufacturing are capital, especially early stage venture capital (VC); a workforce knowledgeable in science, technology, engineering, and mathematics (STEM) disciplines; immigration policies; and industry standards. Demographics play a role: emerging economies tend to have younger populations, and more advanced economies are aging rapidly. These factors are relevant in a globalized marketplace, where national policies drive firm-level decision-making around investment levels in R&D, training, and location of research and manufacturing facilities.

Advanced Manufacturing is not a static entity; rather, it is a moving frontier. What was considered advanced decades ago (pocket-sized personal digital assistants) is now

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traditional, and what is advanced today (portable high-density lithium-ion batteries) will be considered mainstream in the future.

C. Converging Trends in Advanced Manufacturing:-

Over the past few decades, manufacturing has gone from a highly labor-intensive set of mechanical processes to an increasingly sophisticated set of informationtechnology- intensive processes. This trend will continue to accelerate as advances in manufacturing are made. Several broad trends that are changing the face of manufacturing globally are beginning to converge. We consulted experts from academia, government, and industry to identify the broad trends that define these future changes. They identified five large-scale trends applicable to the manufacturing sector: Ubiquitous role of information technology Reliance on modeling and simulation in the manufacturing process Acceleration of innovation in supply-chain management Move toward rapid changeability of manufacturing in response to customer needs and external impediments Acceptance and support of sustainable manufacturingThese trends allow for tighter integration of R&D and production, mass customization, increased automation, and focus on environmental concerns. These trends are not mutually exclusive. This chapter examines these five trends independently and then discusses how their convergence accelerates the emergence of advanced manufacturing enterprises that leverage the trends to their business advantage. Finally, we explain how these trends contributed to the selection of the four technologies that exemplify how advanced manufacturing will change over the coming years.

A. Information Technology:-The first major trend in advanced manufacturing is the increased use of information technology. Numerous examples of information technology exist in the domain of manufacturing, including its support of digital-control systems, asset-management software, computer-aided design (CAD), energy information systems, and integrated sensing—see sidebar on the next page for an example (SMLC 2011).

B. Modeling and SimulationThe second major trend in advanced manufacturing is the use of modeling and simulation across the product life cycle, which may include the development of products, processes, plants, or supply chains. In contrast to information and technology, which primarily drives speed, efficiency, and quality control in production, modeling and simulation approaches are frequently used to move quickly from the design to production stage.

Simulation-based methods for engineering design and analysis have been in development for over 40 years, and they have fundamentally changed the way products are designed (Glotzer et al. 2009). Specific examples include finite-element analysis for solids and computational fluid dynamics for modeling how fluids move in a designed component (Sanders 2011). Unfortunately, limited attention has been directed at developing comparable manufacturing design and analysis capabilities, and as a result, there is a significant gap in the system engineering tool kit that can be usedto optimize producibility.

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C. Innovation of Global Supply-Chain Management:-The third major trend in advanced manufacturing is the management of complex global supply chains. Over the past two decades, several trends have led to more complicated supply chains, among them increasing demand for high-technology goods, globalization, decreasing logistics and communication costs, and the growth of ecommerce (Macher and Mowery 2008). The management of these supply chains is enabled by advances in information technology, such as enterprise resource planning software and radio frequency identification (RFID) technology in logisticsAs supply chains have globalized and become more complex, business executives have become more concerned with the associated risks (Kouvelis, Chambers, and Wang Innovative supply-chain management reduces the time to fulfill customer orders. For example, while a typical product might be manufactured in a day or two, passing that product through supply and distribution chains often takes a month or two. Thus, improving the organization and structure of the supply chain can matter more than increasing efficiency within the factory . If manufacturing begins to move toward more distributed, decentralized production, supply-chain management and innovation will matter even more.

D. Changeability of Manufacturing:-A fourth trend is the move toward rapid changeability of manufacturing to meet customer needs and respond to external impediments (Wiendahl et al. 2007). Here, “changeability” is used as an overarching term that encompasses the terms that typically describe existing paradigms of changing production capacity. Among these terms are “flexibility” “reconfigurability” “transformability” . The hierarchy of these terms, shown in Figure 3 .

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Figure 3. Schematic of changeability at various product and factory production levels.

The product hierarchy, beginning with the highest level on the ordinate includes theentire product portfolio offered by a company. Moving down the y-axis, the portfolio is reduced to its smaller constituents, beginning with products, then subproducts, workpieces, and ultimately down to individual features. Similarly, the production-level hierarchy at its highest level along the abscissa is the network, which includes the entire geographically separated production enterprise linked through the supply chain. Moving down the hierarchy presents smaller and smaller production units from site level (i.e., factory), to segment level (e.g., facilities for assembly, quality measurement, or packing), to cell or system level (a working area) that produces workpieces and the stations that affect feature-level changes.

D) Non- Traditional Machining Processes (Advanced Manufacturing Processes):-

Non-traditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be used for traditional manufacturing processes.

Extremely hard and brittle materials are difficult to machine by traditional machining processes such as turning, drilling, shaping and milling. Non traditional machining processes, also called advanced manufacturing processes, are employed where traditional machining processes are not feasible, satisfactory or economical due to special reasons as outlined below.

• Very hard fragile materials difficult to clamp for traditional machining • When the work piece is too flexible or slender • When the shape of the part is too complex

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Several types of non-traditional machining processes have been developed to meet extra required machining conditions. When these processes are employed properly, they offer many advantages over non-traditional machining processes. The common non-traditional machining processes are described in this section.

i) Electrical Discharge Machining (EDM) Electrical discharge machining (EDM) is one of the most widely used non-traditional machining processes. The main attraction of EDM over traditional machining processes such as metal cutting using different tools and grinding is that this technique tilizes thermoelectric process to erode undesired materials from the work piece by a series of discrete electrical sparks between the work piece and the electrode. A picture of EDM machine in operation is shown in Figure 1.

Fig 4:- Electrical Discharge MachiningThe traditional machining processes rely on harder tool or abrasive material to remove the softer material whereas non-traditional machining processes such as EDM uses electrical spark or thermal energy to erode unwanted material in order to create desired shape. So, the hardness of the material is no longer a dominating factor for EDM process.

Fig 4.1:- Electrical Discharge Machining

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EDM removes material by discharging an electrical current, normally stored in a capacitor bank, across a small gap between the tool (cathode) and the workpiece (anode) typically in the order of 50 volts/10amps.

A schematic of an EDM process is shown in Figure 2, where the tool and the workpiece are immersed in a dielectric fluid.

Application of EDM :-

The EDM process has the ability to machine hard, difficult-to-machine materials. Parts with complex, precise and irregular shapes for forging, press tools, extrusion dies, difficult internal shapes for aerospace and medical applications can be made by EDM process. Some of the shapes made by EDM process are shown in Figure 3.

Fig: 4.2 Application of EDM

Dielectric fluids :-

Dielectric fluids used in EDM process are hydrocarbon oils, kerosene and deionised water. The functions of the dielectric fluid are to:

• Act as an insulator between the tool and the workpiece.

• Act as coolant.

• Act as a flushing medium for the removal of the chips.

The electrodes for EDM process usually are made of graphite, brass, copper and coppertungsten alloys.

ii) Wire EDM :-EDM, primarily, exists commercially in the form of die-sinking machines and wire-cutting machines (Wire EDM). The concept of wire EDM is shown in Figure 4. In this process, a slowly moving wire travels along a prescribed path and removes material from the

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workpiece. Wire EDM uses electro-thermal mechanisms to cut electrically conductive materials. The material is removed by a series of discrete discharges between the wire electrode and the workpiece in the presence of dieelectirc fluid, which creates a path for each discharge as the fluid becomes ionized in the gap. The area where discharge takes place is heated to extremely high temperature, so that the surface is melted and removed. The removed particles are flushed away by the flowing dielectric fluids.

The wire EDM process can cut intricate components for the electric and aerospace industries. This non-traditional machining process is widely used to pattern tool steel for die manufacturing

Fig 5: Wire EDM

The wires for wire EDM is made of brass, copper, tungsten, molybdenum. Zinc or brass coated wires are also used extensively in this process. The wire used in this process should posses high tensile strength and good electrical conductivity. Wire EDM can also employ to cut cylindrical objects with high precision.

3D Printing:-

Invented by a man named Chuck Hull back in 1986, 3D printing is a process of taking a digital 3D model and turning that digital file into a physical object. While Hull went on to launch one of the world’s  largest 3-D printer manufacturers, 3D Systems, his invention concentrated solely on a fabrication process called Stereolithography (SLA). Since that time numerous other 3D printing technologies have been developed, such as Fused Deposition Modeling (FDM)/Fused Filament Fabrication (FFF), Selective Laser Sintering (SLS), PolyJetting and others, all of which rely on layer-by-layer fabrication and are based on a computer code fed to the printer.

While there are numerous technologies which can be used to 3D print an object, the majority of 3D printers one will find within a home or an office setting are based on the FDM/FFF or SLA processes, as these technologies are currently cheaper and easier to

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implement within a machine. We will go further into detail about these technologies and others a little bit later.

‘3D printing’ can also be referred to as ‘additive manufacturing,’ especially when

referring to its use within a manufacturing setting, and many individuals will used both

phrases interchangeably.

Fig 6:- 3-D Printer

How Do 3D Printers Work?

This is a broad question, which was partially explained in the section above. With that

said, the best way to really understand how 3D printing works is to understand the various

technologies involved. Similarly to the way that engines function based on some of the same

principles as one another, but don’t all use gasoline or solar power, all 3D printers don’t use

the same base technology, but still manage to accomplish the same basic tasks. Before we get

into each of these individual technologies, however, one should understand the basic

principles of transferring a 3D model on a computer screen to a 3D printer.

Computers are not like humans; they can’t just look at a 3D model and simply tell

their friend ‘Mr. 3D Printer’ what to print. Lot’s of 1s and 0s are involved, meaning lots and

lots of computer code. Once a 3D model is designed or simply downloaded off of a

repository likeThingiverse, the file (these usually have extensions such as 3MF, STL, OBJ,

PLY, etc.) must be converted into something called G-code.

G-code is a numerical control computer language used mainly for computer

aided manufacturing (both subtractive and additive manufacturing). It is a language which

tells a machine how to move. Without G-code there would be no way for the computer to

communicate where to deposit, cure or sinter a material during the fabrication process.

Programs such as Slic3r are required in order to convert 3D model files into G-code. Once

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the G-code is created it can be sent to the 3D printer, providing a blueprint as to what its next

several thousand moves will consist of. These steps all add up to the complete fabrication of a

physical object. There are other computer languages out there and perhaps many will

eventually gain popularity, but for now G-code is by far the most important.

3D Printing Uses:-i) Medicine:

3D printed models of human organs have been a frequent tool for surgeons over the last two

to three years, as they provide a more intricate view of the issues at hand. Instead of relying

on 2D and 3D images on a computer screen or a printout, surgeons can actually touch and

feel physical replicas of the patient’s organs, bone structures, or whatever else they are about

to work on.

ii) Aerospace:

Because of the unique geometries offered by additive manufacturing, militaries around the

world, as well as agencies such as NASA and the ESA, along with numerous aircraft

manufacturers are turning to 3D printing in order to reduce the overall weight of their aircraft.

Complex geometries and new materials offer superior strength with less mass, potentially

saving organizations like NASA boatloads of fuel, and thus money, during the launching of

spacecraft and/or rockets out of our atmosphere

iii) Prototyping:

Manufacturing facilities across the globe are using 3D printing as a way to reduce costs, save

time, and produce better products. By no longer needing to outsource the prototyping of

parts, companies are able to quickly iterate upon designs on the fly, oftentimes saving weeks

of waiting for third parties to return molds or prototypes.

Three types of 3-D printers

FDM or fused deposition modelling STL or stereo lithography powder deposition printing

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