Advanced Machining and Manufacturing Processes

213 Pages·2018·3.952 MB·English

by  Kaushik Kumar, Divya Zindani, J. Paulo Davim

Materials Forming, Machining and Tribology
Kaushik Kumar · Divya Zindani 
J. Paulo Davim
Advanced
Machining and
Manufacturing
Processes
Materials Forming, Machining and Tribology
Series editor
J. Paulo Davim, Aveiro, Portugal
More information about this series at http://www.springer.com/series/11181
Kaushik Kumar Divya Zindani
(cid:129)
J. Paulo Davim
Advanced Machining
and Manufacturing Processes
123
Kaushik Kumar J.PauloDavim
Department ofMechanical Engineering Department ofMechanical Engineering
Birla Institute of Technology University of Aveiro
Mesra, Ranchi, Jharkhand Aveiro
India Portugal
DivyaZindani
Department ofMechanical Engineering
National Institute ofTechnology
Silchar, Assam
India
ISSN 2195-0911 ISSN 2195-092X (electronic)
Materials Forming,Machining andTribology
ISBN978-3-319-76074-2 ISBN978-3-319-76075-9 (eBook)
https://doi.org/10.1007/978-3-319-76075-9
LibraryofCongressControlNumber:2018936621
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Preface
Adesigncomingoutofthemindofadesignerseeslightoftheday,intheformofa
tangibleproduct,byamanufacturer.Manufacturingindustriesplayapivotalrolein
socio-economic development of a nation. The industries have to compete world-
wide to manufacture the products that not only meet the intended functionality
requirements but are also least detrimental to environment. As a result, industries
keep on hunting for the new manufacturing processes that not only reduces time
and effort but are at the same time eco-friendly. The growing environment of
competitive pressure has lead to the evolution of advanced designing and manu-
facturing concepts. Further, the necessity to use newer materials for different
applications and control of their dimensional accuracies has led to evolution of
modern manufacturing methods or processes.
Mainobjectiveofthisbookistointroduceandexplorethevarioustechniquesin
advancedmanufacturingtechnologies.Itisalsoaimedtoexploreitsefficacyandits
application towards effective product development. The main emphasis, hence, is
directed towards industrial engineering outlook. The target audience is academics
students, researchers and industry practitioners, engineers, research scientists/
academicians working in this vast field.
This book is divided into three parts that provide coverage of the various
advanced manufacturing processes that may be employed by manufacturing
industries to improve their productivity with the sole motive of socio-economic
development.
Part I deals with Automated Conventional Machining Techniques. The part
contains four chapters. Chapter 1 describes the basic principles and functions of
machine tools. It introduces the reader to various material removal techniques
emphasizingon‘formandsize’.Itthenmovestowardsthekinematicsprinciplesof
machining operation including generation, copying and forming. The chapter ends
with concept of surface texture.
Chapter 2 deals with different control mechanism of machine tools. After an
introduction,ittalksaboutthevariouslevelsofcontrolandstartswithzerolevelof
control,then first levelofcontrol,then second levelofcontrolandsoon.Itfinally
directs the attention of the readers to fifth level of control, i.e. numerical control.
v
vi Preface
From here on, the chapter moves towards computer numerical control, explaining
functions, controls, In-process compensation, diagnostics and advantages of CNC
systems. The chapter further explores direct numerical control or DNC detailing
components and functions of the same. The chapter concludes with discussion on
adaptive control of machining systems.
AlthoughChap.2dealswithnumericalcontrol,butChap.3goesdeeperintothe
concept and introduces with its basic components and program of instructions. It
talks about controller unit, machine tool, NC procedure, process planning, part
programming. It also discusses topic like Tape preparation, tape verification and
production.TheprogrammingofanNCsystemcannotbeperformedwithoutsome
basicknowledge,andhence,thechapteralsohighlightsNCcoordinatesystem,NC
motion control systems involving point-to-point NC, straight-cut NC, contouring
NC. Applications of NC systems, its advantages and disadvantages are the con-
cluding part of the chapter.
Chapter4,thelastchapterofthepart,providesthereaderwithsomeillustrations
of part programming in CNC lathe, CNC milling and CNC electrical discharge
machining (EDM) for different operations including a discussion on coordinate
system, dimensioning basics. It also provides an insight on miscellaneous and
preparatory functions, i.e. M-Codes and G-Codes for various operations.
PartIIcoversNonConventionalMachiningTechniques.Thepartcontainssix
chapters. Chapter 5 describes traditional (or conventional) machining techniques
and introduces to the concept of non-traditional (or non-conventional) techniques.
The chapter starts with the fundamental difference between conventional and
non-conventional machining techniques and highlights the requirements of
non-conventional machining techniques.
Non-conventional techniques are ones in which there is no physical contact
between the tool and work-piece and hence requires different energy sources for
such process. They are thermal, mechanical and chemical and electrochemical.
Chapter 6 deals with mechanical machining processes. It includes detailed dis-
cussion on ultrasonic machining, water jet machining, abrasive jet machining,
abrasive water jet machining, ice jet machining and magnetic abrasive finishing.
Foreachofthetechnique, discussionincludes working principle,material removal
rate, applications, advantages and disadvantages.
Chapter7discusseschemicalmachiningtechniquesincludingchemicalmilling,
photochemical milling and electro-polishing. Alike to the earlier chapter, here also
theprocesses aredescribedindetailsincluding process,performance,applications,
advantages and disadvantages.
Chapter 8 deals with electrochemical processes. The description includes elec-
trochemical machining, electrochemical drilling, shaped tube electrolytic machin-
ing, electrostream (capillary) drilling, electrochemical jet drilling and
electrochemical deburring. Following the trends of the earlier chapters, here also
various processes are focused with working, tools, process parameters, output,
applications, advantages and disadvantages.
Preface vii
In Chap. 9, thermal processes are discussed. It includes electro-discharge
machining (EDM), electro-discharge drilling (EDD), electro-discharge milling,
micro-EDM, laser beam machining, laser-based cross/hybrid/assisted machining,
electronbeammachining,plasmabeammachiningandIonbeammachining(IBM).
The discussion on each of the processes is dedicated to working, tools, process
parameters, output, applications, advantages and disadvantages.
Today is the era of hybridization. Hence, the last chapter of the part, i.e.
Chap. 10, talks about processes which are a hybrid of the above techniques like
hybrid electrochemical process, electrochemical honing, electrochemical superfin-
ishing, electrochemical buffing, ultrasonic-assisted ECM and laser-assisted ECM.
Each of them are explained lucidly including the working, process parameters,
output characteristics, accuracy, applications, advantages and disadvantages.
The last part of the book Part III focuses on another budding concept Virtual
Manufacturing, i.e. manufacturing on computers. Today in manufacturing world,
words like Internet of Things (IoT), Big Data, Industry 4.0 (I40) wherein amal-
gamationofInternetandinformationandcommunicationtechnologies(ICTs)with
traditionalmanufacturingprocessesarebeingutilized.Virtualmanufacturingisthe
stepping stone for the same. This part comprises of three chapters. Chapter 11
introduces the reader to the concept of virtual manufacturing, providing the tax-
onomyandvirtualmanufacturingandvirtualmachinetool.Itemphasizesonvirtual
reality-basedsystems,associatedmathematicalmodellingandhardwareinteraction.
In order to allow the readers to have a feel of the subject, Chap. 12 illustrates a
casestudyofvirtualmanufacturingofatransmissionelement(Gear).Acustomeris
allowed to input the various requirements in different rollouts created using a
software (in present case on a 3D Max Studio Platform) and gets the virtual
product.Inthemanufacturingsequel,customervisualizestransformationofablank
to a gear with formation of chips making it realistic. Various programs and the
rollouts are shown for the convenience.
Chapter 13, the last chapter of the part and also the book, explores scope,
socio-economic aspects and future trends of virtual manufacturing. It deals with
design-centred, production-centred and control-centred virtual manufacturing. It
discusses the economics and socio-economic aspects also. A review has been
provided to explain the trends and exploitable results in machine tool, automotive
andaerospacesectors.Itendswithanoteonfuturescopeofvirtualmanufacturing.
First and foremost, we would like to thank God. In the process of putting this
booktogether,itwasrealizedhowtruethisgiftofwritingisforanyone.Youhave
given the power to believe in passion, hard work and pursue dreams. This could
never have been done without the faith in You, the Almighty. We would like to
thankallofourcolleagues,friendsindifferentpartsoftheworldforsharingideasin
shaping our thoughts. We are grateful to all quality managers whose kind contri-
bution helped in shaping this. Our efforts will come to a level of satisfaction if the
professionals concerned with all the fields related to manufacturing processes will
get benefitted. We owe a huge thanks to all of our technical reviewers, editorial
advisory board members, book development editor and the team of publisher
Springer International Publishing AG for their availability for work on this huge
viii Preface
project. All of their efforts helped to make this book complete, and we couldn’t
have done it without them.
Throughout the process of writing this book, many individuals, from different
walks of life, have taken time out to help us out. Last, but definitely not least, we
wouldliketothankthemall,ourwell-wishers,forprovidingusencouragement.We
would have probably given up without their support.
Ranchi, India Kaushik Kumar
Silchar, India Divya Zindani
Aveiro, Portugal J. Paulo Davim
Contents
Part I Automated Conventional Machining Techniques
1 Machine Tools: Numerical Control Perspective . . . . . . . . . . . . . . . 3
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Material Removal Techniques . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Form and Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Kinematics Principles of Machining Operation . . . . . . . . . . . . . 6
1.4.1 Generation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.2 Copying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.3 Forming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.4 Surface Texture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Machine Tool Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Levels of Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.1 Zero Level of Control. . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.2 First Level of Control. . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.3 Second Level of Control. . . . . . . . . . . . . . . . . . . . . . . 10
2.2.4 Third Level of Control . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.5 Fourth Level of Control . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.6 Fifth Level of Control: Numerical Control. . . . . . . . . . 11
2.3 Computer Numerical Control. . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 Functions of CNC . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.2 Advantages of CNC Systems . . . . . . . . . . . . . . . . . . . 14
2.4 Direct Numerical Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4.1 Components of DNC Systems. . . . . . . . . . . . . . . . . . . 14
2.4.2 Functions of DNC . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.3 Advantages of DNC. . . . . . . . . . . . . . . . . . . . . . . . . . 16
ix