Additive and Subtractive Manufacturing Processes Principles and Applications

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.

Chapter 1 Evolution of Manufacturing: Growing on a Circular TrackUday Shanker Dixit1.1Introduction1.2Transformation of manufacturing system: domestic-factory-domestic1.3Customization to mass production to mass-customization and again to customization1.4Importance of sustainability in manufacturing sector1.5Role of data and analytics in manufacturing1.6Influence of evolutions in material science1.7Automation1.8Future of manufacturing1.9Challenges1.10Conclusion Chatper 2 Grinding and recent trends Kamal Kishore, Manoj Kumar Sinha, Dinesh Setti2.1Introduction2.2Sustainable Machining Techniques2.2.1Minimum Quantity Lubrication (MQL)2.2.2Nanofluid MQL2.2.3Cryogenic Cooling2.2.4Hybrid Cooling Methods2.3Hybrid Grinding Techniques2.3.1Ultrasonic Assisted Grinding (UAG)2.3.2Laser-assisted Grinding (LAG)2.4Micro-grinding2.5High-Speed Grinding (HSG)2.5.1Creep Feed Grinding2.5.2High-Efficiency Deep Grinding (HEDG)2.5.3Speed Stroke Grinding (SSG)2.6Textured Grinding Wheel (TGW)2.73D-printed Grinding Wheels2.8Artificial Intelligence (AI) in grinding2.8.1Self-Optimising Programs Systems2.9Precision Shaped Grits2.10Summary Chapter 3 Recent advances in ultrasonic manufacturing and its industrial applications Ravinder P. Singh, Vishal Gupta , Girish C. Verma , Pulak M. Pandey, Uday S. Dixit 3.1Introduction3.2Basic concept3.2.1Mechanics of cutting UAMc process3.2.2Influence on the cutting mechanism3.3Mechatronics involved in UAMc3.4Ultrasonic assisted machining (UAMc) economic aspect3.5Influence of ultrasonic effect on various machining processes3.5.1UAT process3.5.2Ultrasonic assisted milling (UAM) process3.5.3Ultrasonic assisted drilling3.6Industrial application of UAM and RUD process3.6.1Case study on UAM process3.6.2Case study of RUD in biomedical application3.7ConclusionChapter 4 Environmental Sustainability Assessment of a Milling Process using LCA: A Case Study of India Nitesh Sihag, Vikrant Bhakar, Kuldip Singh Sangwan 4.1Introduction4.2Materials and Method4.2.1Goal and Scope Definition4.2.2Functional Unit and System Boundary4.2.3Reference Factory and HVAC System4.2.4Inventory Analysis4.3Results and Discussion4.3.1Endpoint Assessment4.3.2Midpoint Assessment4.4Practical Implications and Recommendations4.5Sensitivity Analysis4.6Summary Chapter 5 Mechanical based non-conventional machining processesRajesh Babbar, Aviral Misra, Girish Verma, Pulak M. Pandey 5.1Introduction5.2Abrasive jet machining5.2.1Mechanism of material removal in AJM5.2.2Process parameters of AJM5.2.3Applications of AJM5.3Abrasive water jet machining5.3.1Material removal mechanism in AWJM5.3.2Process parameters of AWJM5.3.3Cutting geometry in AWJM5.3.4Applications of AWJM5.4Magnetic abrasive finishing5.4.1Material removal mechanism in MAF process5.4.2Process parameters of MAF5.4.3Advances and application of MAF5.4.4Future scope of MAF5.5Abrasive flow machining5.5.1Mechanism of material removal in AFM5.5.2Process Parameters of AFM5.5.3Developments and application of AFM5.5.4Future scope of AFM5.6Conclusion Chapter 6 Thermal Energy Based Advanced Manufacturing Processes Hardik Beravala, Nishant K. Singh 6.1Introduction6.2Air/gas assisted EDM6.3Magnetic field assisted EDM6.4Magnetic field and Air/gas Assisted EDM6.5Conclusions Chapter 7 Polymer based additive manufacturing Narinder Singh, Buta Singh 7.1Introduction7.2Various techniques used in AM7.2.1Fused deposition modeling7.2.2Stereolithography (SLA)7.2.3Laminated object manufacturing7.2.4Selective laser sintering (SLS)7.2.5Laser engineered net shaping (LENS)7.2.6Polyjet7.3HT thermoplastics in additive manufacturing: Structure7.4HT engineering thermoplastics in PBF7.5High performance polymers (HPPs)7.5.1Amorphous HPPs7.5.2Polysulfone7.5.3Polyetherimide7.5.4Poly (phenylene sulfide) and Semi-crystalline HPPs7.5.5Polyether-ether-ketone7.5.6Liquid crystalline polymers7.5.7Nano-based materials/Innovative polymers7.5.8Poly butylene succinate7.5.9Poly hydroxy alkanoates7.5.10Lignin7.6Challenges in printing with HT engineering thermoplastics7.7Conclusions Chapter 8 Recent Research progress and Future Prospects in the Additive Manufacturing of Biomedical Magnesium and Titanium Implants Haytham Elgazzar and Khalid Abdelghany 8.1Introduction8.2Additive Manufacturing and fabrications challenges of biomedical metal implants8.3The fabrication of Ti6Al4V implants using SLM process8.4Biomedical Ti6Al4V implants: Case studies8.5The fabrication of Mg implants using SLM process8.6Post-processing of SLM products8.7Summary and future works Chapter 9 Indirect rapid tooling methods in additive manufacturingGurminder Singh, Pawan Sharma, Kedarnath Rane, Sunpreet Singh 9.1Introduction9.2Indirect rapid tooling9.3Direct rapid tooling9.4Soft Tooling9.5Pattern quality by AM process9.6Different rapid tooling processes9.6.1Electroforming9.6.2Casting9.6.3Investment casting9.6.4Sand casting9.7Sintering9.7.1Conventional Sintering9.7.2Microwave Sintering9.7.3Ultrasonic Vibration Sintering9.8Applications of indirect RT methods9.8.1Machining tools9.8.2Biomedical9.8.3Others9.9Benefits of rapid tooling9.10Future Scope and summary Chapter 10 Laser Additive Manufacturing of Nickel Superalloys for Aerospace ApplicationsS K Nayak , A N Jinoop, S Shiva, C P Paul 10.1Introduction10.2LAM of Ni-superalloys10.3LAM processes10.4LAM Processed Ni-Superalloys for Aerospace Applications10.4.1Inconel 718 (IN718)10.4.2LPBF of IN71810.4.3LDED of IN71810.4.4Inconel 625 (IN625)10.4.5LPBF of IN62510.4.6LDED of IN62510.5Hastelloy-X(HX)10.5.1LPBF of HX10.5.2LPBF of HX10.6Waspaloy10.6.1LPBF of Waspaloy10.6.2LPBF of Waspaloy10.7CM247LC23510.7.1LPBF of CM247LC10.7.2LPBF of IN62510.8Recent Trends in LAM of Ni-Superalloys10.8.1Case studies for LAM built Ni super-alloys for aerospace applications10.9Future Scope10.10Conclusions Chapter 11 Impact of enabling factors on the adoption of additive manufacturing in the automotive industry Kshitij Sharma, Maitrik Shah, Shivendru Mathur, Neha Choudhary, Varun Sharma 11.1Introduction11.2Research motivation11.3Literature review11.3.1Enablers11.3.2Research gap and objective11.4Research method11.5Methodology11.6Interpretive structural modeling (ISM)11.7Analytic network process (ANP)11.8Application and results11.8.1ISM APPLICATION11.8.2ANP application11.9Discussion11.10Managerial implication11.11Conclusions Chapter 12 Thermal Analysis and Melt Flow Behavior of Ethylene Vinyl Acetate (EVA) for Additive Manufacturing Vivek Dhimole, Narendra Kumar, Prashant K. Jain 12.1Introduction12.2Material and methods12.3Results and Discussions12.3.1Thermal analysis of Material Deposition Tool system12.3.2Simulation of melt flow in Barrel12.3.3Simulation of melt flow in Nozzle12.3.4Free extrusion and swelling of melt12.3.5Evolution of temperature distribution along the raster12.4Conclusion Chapter 13 Directed Energy Deposition for metalsNitish P. Gokhale and Prateek Kala 13.1Introduction:13.2Classification of DED processes:13.3Material feeding:13.3.1Wire Feeding:13.3.2Omni-directional wire feeding13.3.3Powder Feeding:13.4Materials for DED processes:13.5Influence of process parameters:13.6Mechanical properties and microstructure:13.7Advantages and disadvantages of DED processes:

Dr. Varun Sharma completed his B.Tech. degree from Guru Nanak Dev Engineering College in 2011securing first position and got Master’s degree from Guru Nanak Dev Engineering College in 2013 in Production Engineering specialization. He joined IIT Roorkee as a faculty member in 2018 and presently serving as assistant professor in Department of Mechanical and Industrial Engineering at Indian Institute of Technology, Roorkee, Uttarakhand, India. He has 8 years of experience in research and teaching. He has published 35 research papers in peer reviewed journals and 11 in national and international conferences. His research interest includes Conventional machining processes, Non-conventional machining processes, Machining and process optimization, Ultrasonic assisted machining, Additive manufacturing/ 3D Printing, Mechanical and biomedical applications. Dr. Pulak M. Pandey completed his B.Tech. degree from H.B.T.I. Kanpur in 1993 securing first position and got Master’s degree from IIT Kanpur in 1995 in Manufacturing Science specialization. He served H.B.T.I. Kanpur as faculty member for approximately 8 years and also completed Ph.D. in the area of Additive Manufacturing/3D Printing from IIT Kanpur in 2003. He joined IIT Delhi as a faculty member in 2004 and is presently serving as Professor. In IIT Delhi, Dr Pandey diversified his research areas in the field of micro and nano finishing, micro-deposition and also continued working in the area of 3D Printing. He supervised 41 PhDs and more than 36 MTech theses in last 10 years and also filed 22 Indian patent applications. He has approximately 201 international journal papers and 48 international/national refereed conference papers to his credit. These papers have been cited for more than 7575 times with h-index as 43. He received Highly Commended Paper Award by Rapid Prototyping Journal for the paper "Fabrication of three dimensional open porous regular structure of PA 2200 for enhanced strnegth of scaffold using selective laser sintering" published in 2017. Many of his B.Tech. and M.Tech. supervised projects have been awarded by IIT Delhi. He is recipient of Outstanding Young Faculty Fellowship (IIT Delhi) sponsored by Kusuma Trust, Gibraltar and J.M. Mahajan outstanding teacher award of IIT Delhi. His students have won GYTI (Gandhian Young Technological Innovation Award) in 2013, 2015, 2017, 2018 and 2020 .