Introduction, Waterjet, Hydroforming

1 INTRODUCTION

ADVANCED MANUFACTURING PROCESSES

Advanced manufacturing is the use of innovative technologies and methodologies for improved competitiveness in the manufacturing sectors.

4 jumps in manufacturing:

1. Steam engine in England, local development → 1^st Industrial Revolution
2. Mass production, after WWII → 2^nd Industrial Revolution
3. Computers invaded manufacturing processes → 3^rd Industrial Revolution
4. Internet → 4.0 Industry

Example: MACHINING

• Conventional: add tools to remove material through mechanical forces
• Unconventional: any other forms of energy and usually not solid tools

TECHNOLOGY

• PROCESS (physical transformation that takes place)
• SYSTEM (machine, tool, features belonging to the machine, all the devices: mech, electronics, also operator...)
• PRODUCT (what we want to obtain at the end of the process
  • WORKPIECE - while working
  • PART - only after we have finished it

The interaction of these 3 makes a technology.

WHY?

Why do we need unconventional processes?

The main drivers of manufacturing are: COST, QUALITY, TIMEWe need FLEXIBILITY = capability to rapidly changing the production to obtain CUSTOMIZATION.This is the era of MASS CUSTOMIZATION, so we need PRODUCTIVITY and FLEXIBILITY.

New processes are being developed for these reasons:

• MATERIAL ADVANTAGE to make technically and economically feasible the manufacturing of new / advanced materials (ceramics, titanium alloys, ...)
• GEOMETRICAL AND PERFORMANCE ADVANTAGE
  • Complex part geometries not obtainable with conventional processes (large undercuts, thin and small components)
  • Higher tolerances or lower roughness needed
  • No residual stresses on the part

1

1. INTRODUCTION

ADVANCED MANUFACTURING PROCESSES

ADVANCED MANUFACTURING is the use of innovative technologies and methodologies for improved competitiveness in the manufacturing sectors.

4 JUMPS in manufacturing:

1. Steam engine in England, local development => 1^st INDUSTRIAL REVOLUTION
2. Mass production, after WWII => 2^nd INDUSTRIAL REVOLUTION
3. Computers invaded manufacturing processes => 3^rd INDUSTRIAL REVOLUTION
4. Internet -> 4.0 INDUSTRY

Example: MACHINING

• -> conventional: add tools to remove material through mechanical forces
• -> unconventional: any other forms of energy and usually not solid tools

TECHNOLOGY

• PROCESS (physical transformation that takes place)
• SYSTEM (machine, tool, features belonging to the machine, all the devices: mech., electronics, also operator...)
• PRODUCT what we want to obtain at the end of the process
  • -> WORKPIECE - while working
  • -> PART - only after we have finished it

The interaction of these 3 makes a technology.

WHY?

Why do we need unconventional processes?

The main drivers of manufacturing are: COST, QUALITY, TIME

We need FLEXIBILITY + capability to rapidly changing the production to obtain CUSTOMIZATION.

This in the era of MASS CUSTOMIZATION, so we need PRODUCTIVITY and FLEXIBILITY.

New processes are being developed for these reasons:

• MATERIAL ADVANTAGE to make technically and economically feasible the manufacturing at new/advanced materials (ceramics, titanium, alloys ...)

• GEOMETRICAL AND PERFORMANCE ADVANTAGE

Complex part geometries not obtainable with conventional processes (large undercuts, thin and small workpieces)

Higher tolerances or lower roughness needed

No residual stresses on the part

• FLEXIBILITY ADVANTAGE to reduce fixed and setup costs and times (reduce costs of tooling and fixtures, dies,...) (reduce time-to-market of a new product) Especially when you have low productions (batches)
  • aerospace manufacturing
  • medical devices

PROCESS

PERFORMANCE can be enhanced by increasing:

• Quality Q
• Flexibility f

• Cost €
• Time t

QUALITY = for a mechanical piece, it is tolerance, mechanical properties, finishing,... The variability is in a ± range, it means you can have different quotes

FLEXIBILITY = ability of a given technology to work with different material, geometry,... it means VERSABILITY, ability of quickly changing the setup (shorten times of setup). Reducing times -> higher flexibility and lower costs

OPTIMIZE

• Quality: no optimization, I have to reach the quality asked by the customer