Trends in Advanced Manufacturing

SVERI’s College of Engineering,Pandharpur 1
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 Paper Presentation On “Trends in Advanced manufacturing Processes”.
A) Introduction:-
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 technology
areas?
 What are emerging trends in advanced manufacturing in specific technology
areas?
 What are enabling factors that affect success in creating advanced
manufacturing 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:-
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 a
critical 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
As the framework depicted in Figure 1
illustrates, advanced manufacturing
involves one or more of the following
elements:
 Advanced products—Advanced
products refer to technologically complex
products, new materials, products with
highly sophisticated designs, and other
innovative 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 enterprise
concepts—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 throughout
the 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.

manufacturing are solely driven by breakthroughs. Because substantive, incremental advances
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

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 manufacturing
These 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 Simulation
The 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.

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 .

Figure 3. Schematic of changeability at various product and factory production levels.
The product hierarchy, beginning with the highest level on the ordinate includes the
entire 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

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 8tilizes
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 Machining
The 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

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

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

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

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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