7th Sem

ADDITIVE MANUFACTURING (BME714A)

What is additive manufacturing technology?

Additive manufacturing (AM) or additive layer manufacturing (ALM) is the industrial production name for 3D printing, a computer controlled process that creates three dimensional objects by depositing materials, usually in layers

How Does Additive Manufacturing Work?

Using computer aided design (CAD) or 3D object scanners, additive manufacturing allows for the creation of objects with precise geometric shapes. These are built layer by layer, as with a 3D printing process, which is in contrast to traditional manufacturing that often requires machining or other techniques to remove surplus material

SYLLABUS

Module - 1

Introduction to Additive Manufacturing

Introduction to AM, AM evolution, Distinction between AM & CNC machining, Advantages of AM, AM process chain: Conceptualization, CAD, conversion to STL, Transfer to AM, STL file manipulation, Machine setup, build , removal and clean up and post processing.

Classification of AM processes: Liquid polymer system, Discrete particle system, Molten material systems and Solid sheet system.

Post processing of AM parts: Support material removal, surface texture improvement, accuracy improvement, aesthetic improvement

AM Applications: Functional models, Pattern for investment and vacuum casting, Medical models, art models, Engineering analysis models,

Rapid tooling, new materials development, Bi-metallic parts, Re-manufacturing. Application examples for Aerospace, defence, automobile, Biomedical and general engineering industries.

Module - 2

System Drives and devices

Hydraulic and pneumatic motors and their features, Electrical motors AC/DC and their features

Actuators: Electrical Actuators; Solenoids, Relays, Diodes, Thyristors, andTriacs. Hydraulic and Pneumatic actuators, Design of Hydraulic and

Pneumatic circuits, Piezoelectric actuators, Shape memory alloys.

Module - 3

POLYMERS & POWDER METALLURGY

Basic Concepts: Introduction to Polymers used for additive manufacturing: polyamide, PF resin, polyesters etc. Classification of polymers, Concept of functionality, Polydispersity and Molecular weight [MW], Molecular Weight Distribution [MWD] Polymer Processing: Methods of spinning for additive manufacturing: Wet spinning, Dry spinning. Biopolymers, Compatibility issues with polymers. Moulding and casting of polymers, Polymer processing techniques

General Concepts: Introduction and History of Powder Metallurgy (PM), Present and Future Trends of PM

Powder Production Techniques: Different Mechanical and Chemical methods, Atomisation of Powder, other emerging processes.

Characterization Techniques: Particle Size & Shape Distribution, Electron Microscopy of Powder, Interparticle Friction, Compression ability

Microstructure Control in Powder: Importance of Microstructure Study, Microstructures of Powder by Different techniques.

Module - 4

NANO MATERIALS & CHARACTERIZATION TECHNIQUES

Introduction: Importance of Nano-technology, Emergence of Nanotechnology, Bottom-up and Top-down approaches, challenges in Nanotechnology Nano-materials Synthesis and Processing: Methods for creating Nanostructures; Processes for producing ultrafine powders- Mechanical grinding; Wet Chemical Synthesis of Nano-materials- sol-gel process; Gas Phase synthesis of Nano-materials- Furnace, Flame assisted ultrasonic spray pyrolysis; Gas Condensation Processing (GPC), Chemical Vapour Condensation(CVC).

Optical Microscopy - principles, Imaging Modes, Applications, Limitations. Scanning Electron Microscopy (SEM) - principles, Imaging Modes, Applications, Limitations. Transmission Electron Microscopy (TEM) - principles, Imaging Modes, Applications, Limitations.X- Ray Diffraction (XRD) - principles, Imaging Modes, Applications, Limitations.Scanning Probe Microscopy

(SPM) - principles, Imaging Modes, Applications, Limitations.Atomic Force Microscopy (AFM) - basic principles, instrumentation, operational modes, Applications, Limitations. Electron Probe Micro Analyzer (EPMA) - Introduction, Sample preparation, Working procedure, Applications, Limitations.

Module - 5

MANUFACTURING CONTROL AND AUTOMATION

CNC technology - An overview: Introduction to NC/CNC/DNC machine tools, Classification of NC /CNC machine tools, Advantage, disadvantages of NC /CNC machine tools, Application of NC/CNC Part programming: CNC programming and introduction, Manual part programming: Basic (Drilling, milling, turning etc.), Special part programming, Advanced part programming, Computer aided part programming (APT)

Introduction: Automation in production system principles and strategies of automation, basic Elements of an automated system. Advanced Automation functions. Levels of Automations, introduction to automation productivity

Control Technologies in Automation: Industrial control system. Process industry vs discrete manufacturing industries. Continuous vs discrete control. Continuous process and its forms. Other control system components.

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