A P ARADIGM SHIFT Presented by Himanshu Bharadwaj II yr Mechanical IIT Powai Lara Sewlani II yr Mechanical IIT Powai
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 1/32
A PARADIGM SHIFT
Presented by
Himanshu BharadwajII yr Mechanical
IIT Powai
Lara SewlaniII yr Mechanical
IIT Powai
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 2/32
Evolution in India Recent cutting edge technologies Rapid prototyping
Major rapid prototyping techniques Comparative view Applications Agile manufacturing
Agile manufacturing + Rapid Prototyping Agile in electronics The paradigm shift Conclusion
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 3/32
1950-1960 : Initial phase of building theindustrial foundation
By 1990 : liberalized sector
By 2010 : 2nd largest global manufacturinghub
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 4/32
Rapidprototyping
High speedmachining
Automation &robotics
nanotechnology
Recenttechnologies
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 5/32
Assembly using three-dimensional computer aideddesign (CAD)
Referred to as solid free-form or layered manufacturing
Manufacturingprocesses
Subtractiveprocesses
Shaping Milling Machining
Additiveprocess
Rapid
prototyping
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 6/32
1. To increase effective communication
2. To decrease development time.
3. To decrease costly mistakes.
4. To test the products.
5. To create ideal models for tooling.
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 7/32
1. A CAD model is constructed.2. The material is processed by creating sliced layers
of the model.3. After each layer model is then lowered by the
thickness of the previous layer.4. After completion the model and any supports are
removed.5. Model is then finished and cleaned.
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 8/32
31.7
18.4
11.2
8.8
8.6
8.2
5.57.7
motor vehicle
consumer
business
(construction)
medical
academic
aerospace
govt.
others
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 9/32
Major RP
technique
SLS
3DPrinting
GPD
SLA
Ink jettechnique
Solidgroundcuring
FDM
LOM BPM
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 10/32
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 11/32
SELECTIVE LASER SINTERING (SLS) ▪ Production parts for unmanned aerial vehicles
▪ One piece fuel tanks
▪ Eliminates use of sub assemblies, adhesives or fasteners
▪ Health care & medical care application
▪ Investment casting process
▪ Gasket & facemask prototype
Industries where applied
▪ Aerospace and military
▪ Automotives
▪ Direct digital manufacturing
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 12/32
Prototypemanufacturing
Pattern masters for
investment casting
Direct tooling forsand casting
Direct tooling for
injection molding
Direct tooling for
die casting
Artificial heart
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 13/32
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 14/32
STEREO LITHOGRAPHY (SLA) ▪ Direct digital applications
▪ Medical & health care
▪ Hardware
▪ Tooling & pattern
▪ Investment casting patterns
▪ Jigs & fixtures
Industries where applied ▪ Health care industries
▪ Automotive components & structures
▪ Military
▪
steel plants
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 15/32
Digital applicationSpring
prototype
Jigs and fixtures
Home hardware Military hardware Human hand
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 16/32
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 17/32
FUSED DEPOSITION MODELLING (FDM) ▪ Fit testing Functional testing,
▪ Rapid tooling patterns, Small detailed parts,
▪ Presentation models,
▪ Patient and food applications
▪ High heat applications
Industries where applied:
▪ Health care industries
▪ Train , rail & car equipment industry
▪ Gas & oil production pipelines
▪ Pharmaceutical industry
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 18/32
Presentation
model
Gas pipeline
prototype
Fit & functional
testing
Building
prototypeSpinal cordprototype Statue
SLS SLA FDM
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 19/32
SLS SLA FDM
ADVANTAGES •Manufacturing of complex geometries
• High mechanical andthermal resistance.
•Rapid delivery time•Rubber like flexible
parts can be made usingelastomer Somos 201
•Low density complexinvestment casting
•Suitable for seals,
gaskets & hightemperature app
•High dimensionalaccuracy
•Greatest accuracywith an excellent
surface finish.•Suitable for making
master models forvacuum casting
process
• Parts can be bead
blasted, painted,textured finished,
electroplated
•Office-friendly and quiet
•FDM is fast for smallparts
•Strong and rigid parts
makes them suitable fortesting
•Dimensional stability is akey advantage
•At times products can bedirectly used as finished
product parts•High level of finish can be
achieved
DIS-ADVANTAGS
•SLS parts have littlerough & porous surface
finish
•Surface finish is not asgood and sharp asproduced by SLA
• Parts are sensitive toheat, moisture and
chemicals
•Not recommended forhigh humidity or
temperature
• Have a ribbedappearance because of
plastic is extruded in
horizontal layers• could be a slower process
for very large parts
MATERIALUSED
• Plastic, metal andelastomeric powders
with CO2 emission
•Photopolymer resinwith UV as emission
laser
•Solid (Filaments),thermoplastics &
elastomers and eutectoids
LIMITATIONS 700 x 380 x 580mm3 508x 508x600mm 203 x 203 x 305mm
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 20/32
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 21/32
Focused on meeting the needs of customers whilemaintaining high standards of quality andcontrolling the overall costs involved
Why is agile manufacturing an effectivestrategy?
Consumer’s love for gratification. Consumer’s love for choice. Consumers are fickle.
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 22/32
o The goal of agile production manufacturing is tooffer customized products at close to the price andspeed of mass-production.
o EXAMPLE….
Earlier there used to be Ford’s one-size fits-allautomobiles.
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 23/32
LEAN MANUFACTURING AGILE MANUFACTURING
Leanness is eliminating ‘wastes’ Eliminating wastes as well as
exploiting opportunities beingflexible and nimble
Cost is the market winner for leanmanufacturing
service levels and responsivenessfor Agile manufacturing.
Mass production as per orderplaced
Customer oriented production
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 24/32
Agile manufacturers are increasingly usingsophisticated CAD/CAM systems.
In addition, some manufacturers are turning tovirtual reality to test their design concepts.
ExampleCaterpillar Inc., for instances using virtual reality totest drive huge earthmoving machines before theyare built
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 25/32
The Product:▪ Conceptual validation: Esthetical, geometrical or
dimensional▪
Functional validation▪ Mechanical, thermal or any physical solicitation
validation▪ Finished machining validation
The Realization mode:▪ Tooling validation▪ Process validation▪ Fabrication cadence validation
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 26/32
Improve reactivity with respect to marketfluctuations
Help creativity and development of new concepts indesign
Simplify communication between customer and
supplier
Focused on configurability, modularity &upgradability of products and long-term satisfaction
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 27/32
Anticipate fabrication, maintenance, control orconditioning problems
Make rapid tests on the product to verify some of itscharacteristics (ergonomic, aerodynamic . .)
Form a part which will be used as a pattern in order
to make a tooling in a very short time.
To address the customers' real needs they must sellsolutions and not products.
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 28/32
Example: The great range, options and degree of customization offered by Dell computers havemade it the current market leader.
Honda’s new range of bikes come with an electronickey containing information that changes theperformance of the machines according to therider’s choice.
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 29/32
Liberalization → increased foreign investments → rapid strides in the field of hi-technologymanufacturing of electronic products.
Problem with electronics manufacturing is the“Constant change in technology to suit the trends and
customer requirements.”
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 30/32
OLD NEW
Product driven Customer driven
High product variety is bad High product variety is good
Product replacement Product upgrading
Functional orientation Product orientation
Economies of sale Economies of time
Dedicated equipments and jobs Agile equipments and jobsSingle enterprise Network enterprise
Information dynasties Open “seamless” information
Top-down management Vision-driven
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 31/32
SLS had the advantage to process wide range of material
While Agile integrates an organization's people and
technologies through innovative management
RP is an area in which agile plays a key role inprocesses such as SLS,SLA& FDM
Customers changing requirements are the demand while “Agile + RP“ is the only supply satisfying them.
8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING
http://slidepdf.com/reader/full/cutting-edge-technologies-in-manufacturing 32/32
Mechanisms in Selective Laser Sintering and Selective LaserMelting, Prof. Dr. Ir. J.P. Kruth, Ir. P. Mercelis, et al., Dept. of Metallurgy and Materials Engineering, Reviewed, accepted
August 4, 2004 (Pg.44-48). A Study of the STEREO LITHOGRAPHY Process, Deborah M.
Cottrill, Univ. of Wisconsin–Platteville, (Pg.1-6). PROCESSING and CHARACTERISATION of RAPID
PROTOTYPING by Deniz Uzunsoy, Univ. of Birmingham, June
2003, (Pg.27-34). Rapid prototyping : principles and applications by Rafiq
Noorani Journal of Materials Processing Technology 194 (2007) 81–88
RAPID PROTOTYPING PROCESS SELECTION using graph
theory and matrix approach by R. Venkata Raoa,, K.K.
Padmanabhanh i i i l