Chapter 8 E-manufacturing
EM is a system methodology that enables the manufacturing operations
to successfully integrate with the functional objectives of an enterprise
through the use of Internet, tether-free (i.e. wireless, web, etc.)
E-manufacturing, also known as digital manufacturing.
E-manufacturing is the integration of computer and communication technologies throughout the manufacturing
process to increase productivity and flexibility while reducing costs. The goal of e-manufacturing is to enable real-
time decision making, reduce manufacturing cycle time, and improve product quality.
E-manufacturing technology includes enterprise resource planning (ERP), manufacturing execution systems (MES),
computer-aided design (CAD) and computer-aided manufacturing (CAM), product lifecycle management (PLM), and
supply chain management (SCM) systems.
Nano Manufacturing Techniques & Micromachining
Micromachining is the removal of material at the micro level with no constraints.
The term refers to the manufacture of micro materials with the guide of carving systems.
Nanomachining has noticeable focal points like high adaptability and
accuracy.
Some manufacturing processes, which were earlier belonged to microtechnology, have now
further scaled down and now they are in the scope of nanotechnology.
Conti…
Removal of material in the form of chips or debris having the size of the range of microns.
Creating micro features or surface characteristics (especially surface finish) in the micro/nano
level.
Material removal at micro/nano level with no constraint on the size of components being
machined.
NANO MANUFACTURING
Nano-technology is a term used for measuring and
manufacturing very smaller devices beyond micro-devices,
which involves the control of feature sizes measured on the
nanometer.
Nano-technology is a multi-disciplinary area of applied
science and engineering that deals with the design and
manufacture of extremely small components and systems.
NANOMANUFACTURING TECHNOLOGY ENCOMPASSES THE PRODUCTION OF
MATERIALS AND DEVICES AT THE NANOSCALE, TYPICALLY BETWEEN ONE AND
100 NANOMETERS.
Need of Micro Machining/ Nano manufacturing/
Micromachining allows engineers to create small, intricate parts.
Final finishing operation in manufacturing of precise parts are always of
concern owing to their most critical, labour intensive & least controllable
nature.
In the era of nanotechnology , deterministic high precision finishing methods
are of utmost importance & are the need of present manufacturing scenario.
The need for high precision in manufacturing was felt by manufacturers
worldwide to improve interchangeability of components, improve quality
control & longer wear/fatigue life.
High Speed Machining and Hot machining
High speed machining can be used most any time you want better tool life and
faster cycle times, but it is particular advantageous for tough materials (like
stainless steel and titanium) as well as particular situations that are hard on tools
such as micromachining.
Characteristics:
Machining at a high cutting speed (Vc).
Machining with a high spindle speed (N).
Machining with a high feed rate (Vf).
Machining with a high removal rate (MRR)
High speed machining (HSM) is a milling technique that focuses on extremely fast but light,
low pressure cuts. It refers to high feed rates and spindle speed for removing material
without compromising part quality and precision5.
The major advantage of HSM is fast cycle time and better tool life5. HSM is used to
manufacture molds with complex core and cavity geometries, as well as structural parts in
the aerospace industry
High speed machining (HSM)–also called trochoidal milling, adaptive clearing, volumill,
and more–is a milling technique that can increase material removal rates, reduce cycle time,
and increase tool life by reducing tool wear.
High-speed machining (HSM) is an advanced manufacturing process that involves using cutting tools at high speeds to
machine parts more efficiently and quickly than conventional methods. It’s characterized by:
Fast spindle speeds
High feed rates
Light, low-pressure cuts
The goal of HSM is to achieve a high material removal rate, which is done by combining lighter milling passes with high
spindle speeds and feed rates1. This method reduces cycle time, extends tool life, and boosts shop productivity2.
Hot machining
Hot machining is a process in which work piece has to be heated below
recrystallization temperature but in some cases it has been also heated above
recrystallization temperature.
The hot machining operation is based on the softening phenomenon at the
vicinity of shear zone (deformation zone).
Hot machining can be applied to machine any hard material to manufacture
industrial products.
Due to external heat supply, the hot machining operations can be applied for
different operations such as turning and milling operations.
HOT MACHINING IS A METHOD TO EXTERNALLY
HEAT THE WORKPIECE MATERIAL BEFORE OR
DURING MACHINING OPERATION. AS A RESULT, THE
SOFTENED MATERIAL WOULD BE MACHINED EASILY
TO REDUCE TOOL WEAR AND INCREASE
PRODUCTION RATE
Micro-wave processing of materials
Energy is supplied by an electromagnetic field directly to the material.
This results in rapid heating throughout the material thickness with reduced
thermal gradients.
Volumetric heating can also reduce processing times and save energy.
The raw material for production of micro-system technologies and devices is
the silicon.
Silicon has a good material properties, such as electronic and mechanical
Microwave processing of materials refers to the use of microwaves to heat and process
various materials. Unlike conventional heating methods, microwave energy is supplied by
an electromagnetic field directly to the material, resulting in rapid, volumetric heating
throughout the material’s thickness. This method can reduce thermal gradients, processing
times, and energy consumption1. It’s applicable to a range of materials including metal
matrix composites, fiber-reinforced polymers, alloys, ceramics, metals, powder metallurgy,
material coatings, and claddings2. The technique leverages the interaction between
microwaves and the material’s molecules, leading to efficient heating and processing
CONTI…
The microwave processing of materials is a relatively new technology that
provides new approaches to improve the physical properties of materials;
provides alternatives for processing materials that are hard to process;
Reduces the environmental impact of materials processing; provides
economic advantages through the saving of energy, space, and time; and
Provides an opportunity to produce new materials and microstructures that
cannot be achieved by other methods.
Cont..
Microwaves are used extensively for communication, both in
satellite television and for the transmission of long-distance
telephone signals.
Disadvantages associated with microwave preparation include
the complexity of the microwave heating phenomena, lack of
heating uniformity, and the need for proper heating control
devices . Uneven temperatures during microwave food heating
remain a major concern.
MICROWAVE APPLICATIONS
food processing,
analytical chemistry, and heating
and
vulcanization of rubber.
Limitation of microwave processing
the cost of equipment; "
limited applicability;
variation in dielectric properties with temperature; and the
inherent inefficiency of electric power.
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