Additive and Subtractive Manufacturing Processes: Principles and Applications

✍ Scribed by Varun Sharma (editor), Pulak Mohan Pandey (editor)

• Publisher: CRC Press
• Year: 2022
• Tongue: English
• Leaves: 317
• Edition: 1
• Category: Library

✦ Synopsis

This reference text discusses fundamentals, classification, principles, applications of additive and subtractive manufacturing processes in a single volume.

The text discusses 3D printing techniques with the help of practical case studies, covers rapid tooling using microwave sintering and ultrasonic assisted sintering process, and covers different hybrid manufacturing techniques like cryo-MQL, and textured cutting inserts. It covers important topics including green manufacturing, ultrasonic assisted machining, electro thermal based non-conventional machining processes, metal based additive manufacturing, LASER based additive manufacturing, indirect rapid tooling, and polymer based additive manufacturing.

The book:

• Discusses additive and subtractive manufacturing processes in detail
• Covers hybrid manufacturing processes
• Provides life cycle analysis of conventional machining
• Discusses biomedical and industrial applications of additive manufacturing

The text will be useful for senior undergraduate, graduate students, and academic researchers in areas including industrial and manufacturing engineering, mechanical engineering, and production engineering.

Discussing the sustainability aspects of conventional machining in reducing carbon footprint of machining by adopting different hybrid and non-conventional machining processes, this text will be useful for senior undergraduate, graduate students, and academic researchers in areas including industrial and manufacturing engineering, mechanical engineering, and production engineering.

✦ Table of Contents

Cover
Half Title
Title Page
Copyright Page
Table of Contents
Preface
Notes on the Editors
Contributors
Chapter 1: Evolution of Manufacturing: Growing on a Circular Track
1.1 Introduction
1.2 Transformation of the Manufacturing System: Domestic–Factory–Domestic
1.3 Customization to Mass Production to Mass Customization and Again to Customization
1.4 Importance of Sustainability in the Manufacturing Sector
1.5 Role of Data and Analytics in Manufacturing
1.6 Influence of Evolution in Material Science
1.7 Automation
1.8 The Future of Manufacturing
1.9 Challenges
1.10 Conclusion
References
Chapter 2: Grinding and Recent Trends
2.1 Introduction
2.2 Sustainable Machining Techniques
2.2.1 Minimum Quantity Lubrication (MQL)
2.2.2 Nanofluid MQL (nMQL)
2.2.3 Cryogenic Cooling
2.2.4 Hybrid Cooling Methods
2.3 Hybrid Grinding Techniques
2.3.1 Ultrasonic Assisted Grinding (UAG)
2.3.2 Laser-Assisted Grinding (LAG)
2.4 Micro-Grinding
2.5 High-Speed Grinding (HSG)
2.5.1 Creep Feed Grinding
2.5.2 High-Efficiency Deep Grinding (HEDG)
2.5.3 Speed Stroke Grinding (SSG)
2.6 Textured Grinding Wheel (TGW)
2.7 3D Printed Grinding Wheels
2.8 Artificial Intelligence (AI) in Grinding
2.9 Precision Shaped Grits
2.10 Summary
References
Chapter 3: Recent Advances in Ultrasonic Manufacturing and Its Industrial Applications
3.1 Introduction
3.2 Basic Concept
3.2.1 Mechanics of the Cutting UAMc Process
3.2.2 Influence on the Cutting Mechanism
3.3 Mechatronics Involved in UAMc
3.4 The Economic Aspect of UAMc
3.5 Influence of the Ultrasonic Effect on Various Machining Processes
3.5.1 UAT Process
3.5.2 Ultrasonic Assisted Milling (UAM) Process
3.5.3 Ultrasonic Assisted Drilling
3.6 Industrial Application of the UAM and RUD Processes
3.6.1 Case Study of the UAM Process
3.6.2 Case Study of RUD in Biomedical Applications
3.6.3 Histopathological Observation to Study Thermal Necrosis
3.7 Conclusion
References
Chapter 4: An Environmental Sustainability Assessment of a Milling Process using Life Cycle Assessment: A Case Study of India
4.1 Introduction
4.2 Materials and Method
4.2.1 Goal and Scope
4.2.2 Functional Unit and System Boundary
4.2.3 Reference Factory and the HVAC System
4.2.4 Inventory Analysis
4.3 Results and Discussion
4.3.1 Endpoint Assessment
4.3.2 Midpoint Assessment
4.4 Practical Implications and Recommendations
4.5 Sensitivity Analysis
4.6 Summary
References
Chapter 5: Mechanically Based Non-Conventional Machining Processes
5.1 Introduction
5.2 Abrasive Jet Machining
5.2.1 Mechanism of Material Removal in AJM
5.2.2 Process Parameters of AJM
5.2.3 Applications of AJM
5.3 Abrasive Water Jet Machining
5.3.1 Material Removal Mechanism in AWJM
5.3.2 Process Parameters of AWJM
5.3.2.1 Water Jet Pressure
5.3.2.2 Traverse Rate
5.3.2.3 Abrasives
5.3.2.4 Abrasive Mass Flow Rate
5.3.2.5 SOD
5.3.2.6 Jet Impingement Angle ( θ)
5.3.3 Cutting Geometry in AWJM
5.3.4 Applications of AWJM
5.4 Magnetic Abrasive Finishing (MAF)
5.4.1 Material Removal Mechanism in the MAF Process
5.4.2 Process Parameters of MAF
5.4.3 Advances and Application of MAF
5.4.4 Future Scope of MAF
5.5 Abrasive Flow Machining
5.5.1 Mechanism of Material Removal in AFM
5.5.2 Process Parameters of AFM
5.5.3 Developments and Application of AFM
5.5.4 Future Scope of AFM
5.6 Conclusion
References
Chapter 6: Thermal-Energy-Based Advanced Manufacturing Processes
6.1 Introduction
6.2 Air/Gas Assisted EDM
6.3 Magnetic Field Assisted EDM
6.4 Magnetic Field and Air/Gas Assisted EDM
6.5 Conclusions
References
Chapter 7: Polymer-Based Additive Manufacturing
7.1 Introduction
7.2 Various Techniques Used in AM
7.2.1 Fused Deposition Modeling
7.2.2 Stereolithography (SLA)
7.2.3 Laminated Object Manufacturing (LOM)
7.2.4 Selective Laser Sintering (SLS)
7.2.5 Laser Engineered Net Shaping (LENS)
7.2.6 Polyjet
7.3 HT Thermoplastics in Additive Manufacturing: Structure
7.4 HT Engineering Thermoplastics in PBF
7.5 High Performance Polymers (HPPs)
7.5.1 Amorphous HPPs
7.5.2 Polysulfone (PSU)
7.5.3 Polyetherimide (PEI)
7.5.4 Poly(phenylene sulfide) (PPS) and Semi-crystalline HPPs
7.5.5 Polyether Ether Ketone (PEEK)
7.5.6 Liquid Crystalline Polymers (LCPs)
7.5.7 Nano-Based Materials/Innovative Polymers
7.5.8 Poly Butylene Succinate (PBS)
7.5.9 Polyhydroxyalkanoates (PHAs)
7.5.10 Lignin
7.6 Challenges in Printing with HT Engineering Thermoplastics
7.7 Conclusions
References
Chapter 8: Recent Research Progress and Future Prospects in the Additive Manufacturing of Biomedical Magnesium and Titanium Implants
8.1 Introduction
8.2 Additive Manufacturing and Fabrication Challenges of Biomedical Metal Implants
8.3 The Fabrication of Ti6Al4V Implants Using the SLM Process
8.4 Biomedical Ti6Al4V Implants: Case Studies
8.5 The Fabrication of Mg Implants Using the SLM Process
8.6 Post-Processing of SLM Products
8.7 Summary and Future Work
References
Chapter 9: Indirect Rapid Tooling Methods in Additive Manufacturing
9.1 Introduction
9.2 Indirect Rapid Tooling
9.3 Direct Rapid Tooling
9.4 Soft Tooling
9.5 Pattern Quality by AM Process
9.6 Different Rapid Tooling Processes
9.6.1 Electroforming
9.6.2 Casting
9.6.3 Investment Casting
9.6.4 Sand Casting
9.7 Sintering
9.7.1 Conventional Sintering
9.7.2 Microwave Sintering
9.7.3 Ultrasonic Vibration Sintering
9.8 Applications of Indirect RT Methods
9.8.1 Machining Tools
9.8.2 Biomedical
9.8.3 Other Applications
9.9 Benefits of Rapid Tooling
9.10 Future Scope and Summary
References
Chapter 10: Laser Additive Manufacturing of Nickel Superalloys for Aerospace Applications
10.1 Introduction
10.2 The LAM of Ni-Superalloys
10.3 LAM Processes
10.4 LAM-Processed Ni-Superalloys for Aerospace Applications
10.4.1 Inconel 718 (IN718)
10.4.2 LPBF of IN718
10.4.3 LDED of IN718
10.4.4 Inconel 625 (IN625)
10.4.5 LPBF of IN625
10.4.6 LDED of IN625
10.5 Hastelloy-X(HX)
10.5.1 LPBF of HX
10.5.2 LPBF of HX
10.6 Waspaloy
10.6.1 LPBF of Waspaloy
10.6.2 LPBF of Waspaloy
10.7 CM247LC
10.7.1 LPBF of CM247LC
10.7.2 LPBF of IN625
10.8 Recent Trends in the LAM of Ni-Superalloys
10.9 Future Scope
10.10 Conclusions
Acknowledgement
References
Chapter 11: Impact of Enabling Factors on the Adoption of Additive Manufacturing in the Automotive Industry
11.1 Introduction
11.2 Research Motivation
11.3 Literature Review
11.3.1 Enablers
11.3.2 Research Gaps and Objectives
11.4 Research Method
11.5 Methodology
11.6 Interpretive Structural Modelling (ISM)
11.7 Analytic Network Process (ANP)
11.8 Application and Results
11.8.1 ISM Application
11.8.2 ANP Application
11.9 Discussion
11.10 Managerial Implications
11.11 Conclusions
References
Chapter 12: Thermal Analysis and the Melt Flow Behavior of Ethylene Vinyl Acetate for Additive Manufacturing
12.1 Introduction
12.2 Material and Methods
12.3 Results and Discussion
12.3.1 Thermal Analysis of the Material Deposition Tool System
12.3.2 Simulation of Melt Flow in the Barrel
12.3.3 Simulation of Melt Flow in the Nozzle
12.3.4 Free Extrusion and the Swelling of Melt
12.3.5 Evolution of Temperature Distribution Along the Rasters
12.4 Conclusion
References
Chapter 13: Directed Energy Deposition for Metals
13.1 Introduction
13.2 Classification of DED Processes
13.3 Material Feeding
13.3.1 Wire Feeding
13.3.2 Omni-Directional Wire Feeding
13.3.3 Powder Feeding
13.4 Materials for DED Processes
13.5 Influence of Process Parameters
13.6 Mechanical Properties and Microstructure
13.7 Advantages and Disadvantages of DED Processes
References
Chapter 14: An Investigation of Active Cutting Energy for Rough and Finish Turning of Alloy Steel
14.1 Introduction
14.2 Materials and Methods
14.2.1 The Taguchi Method
14.2.2 Response Surface Methodology
14.2.3 Workpiece, Cutting Inserts, Input Parameters and Their Levels
14.2.4 Instrument and Equipment
14.3 Experimental Procedure Observations and Calculations for Turning Operations
14.3.1 Optimization of Active Cutting Energy for Turning Operations
14.3.2 Analysis of Variance (ANOVA)
14.3.3 Response Surface Model of ACE for Turning Operations
14.4 Comparative Analysis and Confirmation of Results
14.4.1 Optimal Rough and Finish Turning Parameters Used in Industries
14.5 Conclusions
References
Index