23MTRN08C
Manufacturing
Report
STUDENT NAMES:
MAYAR AYMAN (234643)
MALAK AHMED (232635)
AYA TAREK (233799)
MARK SAMER (229246)
PETER NABIL (236714)
MODULE LEADER:
Prof Iman Elmahallwi
Contents
Table of Figures............................................................................................................................................ 3
Casting and Welding Processes ................................................................................................................... 4
Casting Process ........................................................................................................................................ 4
Welding Process ....................................................................................................................................... 6
Comparing between Sand and Die Casting............................................................................................... 7
Comparing between different Welding Specimens .................................................................................. 11
Microstructure of Welding ........................................................................................................................... 14
Machining Process ..................................................................................................................................... 17
Conventional machining .......................................................................................................................... 17
Benefits of Conventional Machining ..................................................................................................... 18
Drawbacks of Conventional Machining ................................................................................................ 18
Applications and Industries .................................................................................................................. 18
Examples of conventional machining ................................................................................................... 19
Non-conventional machining ................................................................................................................... 22
Benefits of Non-conventional Machining .............................................................................................. 22
Drawbacks of Non-conventional Machining ......................................................................................... 23
Applications and Industries of Non-Conventional Machining ................................................................ 23
Examples of Non-Conventional Machining .......................................................................................... 23
Additive Manufacturing............................................................................................................................ 27
Advantages ......................................................................................................................................... 27
Disadvantages..................................................................................................................................... 27
Applications ......................................................................................................................................... 28
Examples ............................................................................................................................................ 28
Parts Design ........................................................................................................................................... 30
Shaft Collar.......................................................................................................................................... 30
Custom Denture Retainer .................................................................................................................... 31
Table of Contributions ................................................................................................................................ 33
References ................................................................................................................................................. 33
Table of Figures
Figure 1. Sand casting. ................................................................................................................................. 5
Figure 2. Hot Chamber Casting. ................................................................................................................... 6
Figure 3. Cold Chamber Casting. ................................................................................................................. 6
Figure 5. Die Casting Tensile Results. .......................................................................................................... 8
Figure 4. Sand Casting Tensile. .................................................................................................................... 8
Figure 6. Sand Casting Hardness test 1. ...................................................................................................... 8
Figure 7.Sand Casting Hardness Test 2. ...................................................................................................... 9
Figure 8.Sand Casting Hardness Test 3. ...................................................................................................... 9
Figure 9.Die Casting Hardness Test 1. ....................................................................................................... 10
Figure 10.Die Casting Hardness Test 2. ..................................................................................................... 10
Figure 11.Die Casting Hardness Test 3. ..................................................................................................... 11
Figure 12. MIG Stress-Strain. ..................................................................................................................... 12
Figure 13. SMAW Stress-Strain. ................................................................................................................. 12
Figure 14. Gas Welding Stress-Strain......................................................................................................... 13
Figure 15. Spot Welding Stress-Strain. ....................................................................................................... 13
Figure 16. non-welded Stress-Strain........................................................................................................... 13
Figure 17. Non-Welded Stress-Strain. ........................................................................................................ 11
Figure 18. General Machining Cutting Tool................................................................................................. 18
Figure 19. Turning Process ........................................................................................................................ 19
Figure 20. Vertical and Horizontal Milling Process. ..................................................................................... 20
Figure 21. Drill Bit ....................................................................................................................................... 21
Figure 22. Laser Cutting ................................................................................................................................ 24
Figure 23. Electrical Discharge Machining process. .................................................................................... 25
Figure 24. Abrasive Water Jet. ................................................................................................................... 26
Figure 25. Abrasive Jet. .............................................................................................................................. 27
Figure 26. SLA manufacturing. ................................................................................................................... 28
Figure 27. 3D Inkjet. ................................................................................................................................... 29
Figure 28. Fused Filament Fabrication. ...................................................................................................... 30
Figure 29. Shaft Collar. ............................................................................................................................... 31
Figure 30. Custom Denture Retainer. ......................................................................................................... 32
Casting and Welding Processes
Casting Process
Casting is the most significant manufacturing process in the production field. 90% of the products we
use every day are made by casting. casting process is used for high production rates. there are many types of
casting it depends on the material to be cast and the martial of mold and pattern is then specified according
to it.
In casting, the metal is heated to its melting temperature and then poured into the mold with the
desired product shape to solidify at a specific rate to reach the product's desired properties to satisfy its
function. The first type is sand casting which has a wide range of uses, it can go with complicated and
simple shapes. more than 60% of metal products is made using the sand-casting method.
This casting type is lower in the cost of tools and equipment than the other types, but the surface
finish in this process is not perfect. The components in sand casting are mold, pattern, flask, cores, and
gating system. Mold is made of sand that has passed through many processes to change its properties to
reach the final station then it can be used for casting.
The mold is packed under high temperatures to increase its strength to not break while pouring the molten
metal. there are two types of mold processExpendable-mold processes - mold is sacrificed to remove part.
The advantage of this type: more complex shapes are possible, but it also has some Disadvantages as
production rates are often limited by the time to make mold rather than casting itself
Permanent-mold processes - mold is made of metal and can be used to make many castings The
benefits of this mold process are that it has higher production rates. This type has different processing
problems as the geometries are limited by the need to open the mold.. pattern can be made of plastic or
wood. There are many types of patterns used in sand casting such as solid pattern, split pattern,
match‑plate patterns, cope, and drag patterns. The third component is the core. It is used only for products
with internal holes or bores to be removed after solidification. It can be made as a pattern also from wood or
plastic. The furnace is used to melt metal at an extremely high temperature.
The gating system is an essential part of sand casting. It provides stability in the system for creating
a stable design. It consists of a runner, a down sprue, and a channel where the molten metal reaches the
cavity. The riser is wasted metal that is separated from the casting and remelted to make more castings to
minimize waste in the unit operation, the volume of metal in the riser should be a minimum.
(“Understanding the Fundamentals of Metal Casting | PPT - SlideShare”)
Since the shape of the riser is normally designed to maximize the V/A ratio, this allows the
riser volume to be reduced to the minimum possible value.
Figure 1. Sand casting.
2) die casting
The second type of casting is die-casting. The cavity in this process is surrounded by metal instead of
sand so it is a permanent casting process. This cavity is then filled with molten metal.
After the metal solidifies the two dies are opened to remove the product. The final surface
finish is better than sand. There is also cold die casting which provides more strength to the material and
ductility to the material. "The use of salt cores allows complex internal galleries to be formed without
tooling complexity or design compromise." (“Die Casting: Definition, Types, Materials, Applications, and
Benefits”)
1. Hot chamber casting: Metal is melted in a container, and a piston injects liquid metal under high
pressure into the die it gives High production rates.

Figure 2. Hot Chamber Casting.
2. Cold chamber casting : Molten metal is poured into unheated chamber from external melting
container, and a piston injects metal under high pressure into die cavity.
Figure 3. Cold Chamber Casting.
Welding Process
Arc welding uses an electric arc to get the necessary heat to melt and join metal, its divided into
either consumable or non-consumable electrode methods, which determines the role of the electrode.
SMAW stands for shielded metal arc welding, also known as stick welding. Is a process where the
arc strikes between the metal rod (electrode flux coated) and the work piece, both the rod and work piece
surface melt to form a weld pool. Simultaneous melting of the flux coating on the rod will form gas, and
slag, which protects the weld pool from the surrounding atmosphere.
Metal inert gas (MIG) welding joins two pieces of metal, using an electrical supply which fuses the base
metal with a consumable electrode filler.
Also known as gas metal arc welding (GMAW) or simply wire welding, the MIG process differs
from TIG in that it uses a consumable wire that acts as both the electrode and the filler material. Whereas
TIG welding simply relies on a tungsten tip to heat and join the metal surfaces directly.
Spot welding is a resistance welding process, it functions by contacting copper alloy electrodes to the
sheet surfaces, whereby pressure and electric current are applied, and heat is generated by the passage of
current through resistive materials like low carbon steels. It is primarily used for welding two or more metal
sheets together by applying pressure and heat from an electric current to the welded area. (“What is Spot
Welding? (A Complete Welding Process Guide) - TWI”)
Resistance seam welding is a variation of resistance spot welding, primarily distinguished using
motor-driven wheels in place of stationary rods as the welding electrodes. This welding technique, which is
perfect for fabricating sheet metal, involves passing an electric current through the sheets of metal to be
joined while they are held together by a mechanical force in a lap configuration between shaped copper
electrodes. Like other forms of resistance welding, fusion occurs at the point of contact between the sheet
surfaces since this is also the location where heat generation is maximum and there is the greatest electrical
resistance.
Comparing between Sand and Die Casting
There are two types of casting and molding die casting and sand casting. Sand Casting is used to
shape a liquid material to the desired structure as there are shapes that cannot be shaped by die casting, for
example, Engine parts, Brake drums, intake manifolds, and housing also sand casting is used in large
production and is cheaper than die casting in cost of production as sand casting components are base sand
and binding additives that make the sand more attached to each sand grain but sand casting have
disadvantages like poor surface finish and less dimensional accuracy. On the other hand, Die casting is a
casting procedure that involves adding molten non-ferrous alloys into the molded shape of the die under
high pressure at high speed to rapidly cool the melted alloy to create the molded product as die casting is
used in alloys like aluminum while sand casting in metals that have lower melting points and die casting
costs more in manufacturing molded products as there must be a molded metal shape to use the die casting
and have many molded shapes for each wanted shape while sand casting is only sand and binding additives
and can be reused on many other shapes while die casting only one molded shape for each component
needed.
Figure 5. Die Casting Tensile Results.
Figure 4. Sand Casting Tensile.
From figures 1 and 2, we can conclude that sand casting is fatigue as its breakpoint is lower than die
casting as die casting breakpoint at 161.446 MPa and strain of 17.800% while sand casting is at 101.668
MPa and strain of 12.784%.
Figure 6. Sand Casting Hardness test 1.
Figure 7.Sand Casting Hardness Test 2.
Figure 8.Sand Casting Hardness Test 3.
Figure 9.Die Casting Hardness Test 1.
Figure 10.Die Casting Hardness Test 2.
Figure 11.Die Casting Hardness Test 3.
From Figure 3 and Figure 4 we can conclude that die casting has higher hardness as after impact
reading of die casting ranges from 46.3 - 49.7 (HV) while sand casting ranges from 33.6 - 39.9 (HV) so die
casting is harder than sand casting.
Comparing between different Welding Specimens
The welding process requires basic elements such as filler metal, heat source, and shielding flux to
join metals together. In the MIG welding process, an electrode acts as filler metal using a shielding gas,
making it easier to use. It can also be used when the metal (steel, aluminum) is thicker.
Moreover, this specimen had an initial length of 88 mm and a final length of 90 mm after doing the
tensile test with an initial thickness of 6.2mm. The MIG process had tensile strength of 271MPa with a
modulus of elasticity of 6337.5, unfortunately it produces rust unlike the Arc process which can affect its
quality. On the other hand, The Gas welding process uses oxygen fuel gas to join metals together, as gas
welding is considered to have the highest quality outcome as well as precise welds, still, it is a slow process
to work with, also it is only applicable with any thin metals. But it can cause bending while heating on thin
metals. In addition, this process used a metal that started with an initial length of 94mm and a final of
108mm with a thickness of 1.7mm after conducting a tensile test which can be said by its high modulus of
elasticity of 25,284MPa with a tensile strength of 347.35MPa.
The Arc Welding process is flux-based process that works with thicker metals. The metal used by this
process had an initial of 80mm, 6.36mm thick, and a final length of 85mm. Moreover, this process had a
tensile strength of 349.2MPa, and a modulus of elasticity of 5,122. The spot-welding process uses electric
current at chosen points making it an efficient technique in aerospace and automotive industries and its an
ideal use on thin metals unlike base thin and arc welding. This tensile test had an initial length of 75mm and
a final length of 85mm with a thickness of 1.67mm, the conducted test showed a tensile strength of
305.12MPa and modulus of elasticity of 14,937MPa.
Both Base thick and thin processes had a close tensile strength at 395 and 365MPa with a significant
difference in modulus of elasticity at 8,722 and 24,241MPa. They differentiate in the size as well as how
quickly the heat can burn through which is easily controlled in the base thick and can break easily in the
base thin. A common challenge when working with these processes is the lack of fusion.
The Results conclude that the gas and base thick welding has the highest percentage of stiffness. The
MIG process is considered the most at risk of failure due to low tensile strength. The Gas welding process is
the most suitable technique to use as it can endure forces as well as its high stiffness apart from using thin
metals.
Figure 12. MIG Stress-Strain.
Figure 13. SMAW Stress-Strain.
Figure 14. Gas Welding Stress-Strain.
Figure 15. Spot Welding Stress-Strain.
Figure 16. non-welded Stress-Strain.
Figure 17. Non-Welded Stress-Strain.
Microstructure of Welding
In Arc welding base microstructure shows presence of ferrite and martensite phases, which results in low
strength due to large ferrite and high grain boundaries present (close up) affecting the slow cooling rate
causing brittle fracture and high risk of rapid cracking, also the presence of martensite phase contributes to
high tensile strength which shows in the arc welding specimen result. Similarly, Gas welding base has
same phases compared to arc welding and similar properties which makes it close in the result of high
tensile strength.
In Arc welding heat affected zone microstructure shows presence of ferrite and martensite phases, due
to the high increase of martensite grains and finer-ferrite grains this results in rapid cooling which makes it
hard and strong structure. On the other hand, Gas welding heat affected zone has large ferrite grains and
high presence of grain boundaries which causes it to soften and increase in ductility and its low strength.
In Arc welding interface shows large ferrite grains and high martensite grains which leads to low strength
and brittleness, have slow cooling rate. On the other hand, Gas welding interface has high martensite
phase than ferrite which makes it a lot harder than the arc welding interface.
In Arc welding unaffected heat zone microstructure shows ferrite phase present and pearlite with the fine
grains present it is affecting its ductility and overall tensile strength. While pearlite is present in a limited
amount which results in having a high hardness rate due to (ferrite +cementite) present with high tougness
in the structure. Similarly, Gas welding unaffected zone has same phases, but the gas welding is heated
which can affect its properties slightly.
Figure. Arc welding base
Figure. Arc welding (HAZ)
Figure. Arc welding Interface
Figure. Arc welding weld
Figure. Gas welding base
Figure. Gas welding (HAZ)
Figure. Gas welding Interface
Figure. Gas welding weld
Machining Process
Machining is a process in which material is removed from a workpiece to reach a desired geometry. There
are three main types of machining, Conventional, abrasive, and non-traditional machining.
Conventional machining
In conventional machining, a sharp cutting tool is used to remove material from the workpiece. The
three main components in conventional machining are the cutting tools, the work piece, and the machine
itself, and interaction between these three components is what allows machining to occur. The cutting tool
needs specific properties for machining to happen smoothly. First the cutting tool should be significantly
harder than the workpiece. A common material for this is High-speed steel, it is cost effective and is hard
with high toughness which makes it a suitable material for the cutting tool. Another material that is
commonly used is carbide. While more expensive than HSS, it offers higher tensile strength, and can resist
wear better when compared with high-speed steel. Aside from the physical properties, cutting tools should
also exhibit specific geometry as it significantly impacts the performance of the process as well as the
surface finish of the final product.
Figure 18. General Machining Cutting Tool.
The cutting tool geometry involves four main parts. The cutting edge, the rake angle, the clearance
angle, and the relief angle. The cutting edge is the sharp edge of the tool. It is the part of the tool that
removes material from the workpiece. There are many processes under the umbrella of conventional
machining. such as, turning, milling, drilling.
Benefits of Conventional Machining
1- Variety of materials: Conventional machining processes can be used on a variety of different
materials including metals of different hardness, plastics like acrylic and nylon, or wood.
2- Different shapes and geometries: Machining can easily create different regular geometries.
3- Good dimensional accuracy and surface finish: Machining final products have a good final product,
it is sometimes used after forming process to improve their surface finish, and dimensional accuracy.
Drawbacks of Conventional Machining
1- Material Waste: Most machining and other material removal processes involve wasted material; this
material could be recycled but it is considered a waste of unit operations.
2- Time consuming: Machining processes are usually more time consuming compared to other shaping
processes such as casting or forging.
3- Material limitations: While machining processes can work on a lot of varied materials, it cannot
work on hard materials such as titanium, or brittle material like ceramics. It can also not be used on
soft materials like rubber.
Applications and Industries
Machining is generally used after other manufacturing processes to create a cleaner surface finish or
achieve more complex geometries. It is used in many industries to create different products. In general,
conventional machining is used to make hardware such as bolts, nuts, and screws, medical devices such as
surgical instruments or shafts for machinery and equipment. These could be mass produced using different
machining processes. Aching is specifically used in the automotive industry to make engine parts such as
pistons, cylinder heads and crankshafts. Also in the automotive industry, machining is used in the brake
components and even in the suspension components. Another industry that uses machining includes the
aerospace industry, it is used in the landing gear components and some engine parts like the turbine blades.
Examples of conventional machining
Turning machining
Turning is used to make cylindrical shapes, taper edges, or create threads on a workpiece. In the
turning machine the workpiece rotates while a cutting tool moves linearly into the workpiece to remove
material.
Figure 19. Turning Process
The chips produced from turning can either be continuous or non-continuous, a continuous chip
indicates consistency however, the chip could ruin the work piece, the machine or even cause injuries to the
operator of the machine if it breaks in an uncontrolled manner. The chips produced from turning are hard to
recycle so it is often just wasted materials.
Advantages
1- High precision: Turning has close tolerance and accurate dimensions.
2- Wide material compatibility: Turning can be used to machine many different materials.
Disadvantages
1- Limited shapes: Turning is used for cylindrical shapes, more complex shapes might require
multiple machining processes.
2- Size limitations: Size of workpiece is limited to the machine.
3- Initialization: Setting up a turning machine for the first time might require a lot of testing to get
the feed speed, distance, and rotation speed right.
Applications:
1- shafts.
2- Axels
3- Bushings
4- Pipes
Milling machining
Milling offers more shape, geometry, and versatility compared to turning and it uses a rotating
cutting tool, which has multiple cutting edges. The multi-tooth cutting tool removes material from the
workpiece which is stationary. A milling machine can be both vertical and horizontal, the cutting tool in the
machine can move on all three axes.
Figure 20. Vertical and Horizontal Milling Process.
Advantages
1- Geometry versatility: Milling allows for many shapes and can create many features such as slots
and grooves, it can also produce flat surfaces and pockets.
2- High precision: Milling machines can create accurate dimensions and complicated features with
close tolerance.
3- Automation: Most milling machines allow for CNC (Computer Numerical Control) this allows
for efficient automation of the production processes
4- Material versatility: Similarly, to turning, milling can be done on a wide variety of materials.
Disadvantages
1- Complex of operation: Operating a milling machine and setting it up is more complicated than a
turning machine.
2- Time consuming: Milling is more time consuming compared to turning. This is due to the
complex movement the tool is required to make to achieve the desired results.
3- Size limitation: Like turning, milling workpiece size is limited to the capacity of the machine.
Applications:
1- Housings
2- Gears
3- Wing ribs in aerospace components
4- Molds and dies.
Drilling machining
Drilling is used to create cylindrical holes, which have varying diameters and depths in a
workpiece. This is achieved by rotating the cutting tool, the drill bit which has two cutting edges,
into a workpiece. The feed of the drilling machine determines the depths of the cylindrical hole.
Figure 21. Drill Bit
Advantages
1- Simple: Drilling is a simple process relative to both milling and turning
2- Versatile: Drilling is versatile in hole sizes, depths, and materials of the work piece
3- Efficient: Drilling is a fast efficient way to create simple holes in a workpiece
4- Portability: Some drills are portable which can allow drilling operations to occur on site
Disadvantages
1- Limited geometry: Drilling is less versatile when it comes to geometry compared to turning and
milling since it is primarily used to create holes and does not allow for complex geometry.
2- Size limitation: Size of hole is limited to drill bits available.
3- Accuracy: While drilling itself may be accurate hole positioning accuracy may be difficult to
achieve.
Application
The holes created by drilling are used for many things including.
1- Assembly
2- Fastening
3- Dowel joints.
Non-conventional machining
Non-conventional machining involves removal of material without using traditional cutting tools.
While conventional machining uses sharp edge, single or multi-point cutting tools, non-conventional uses
different methods to remove material that does not involve a physical cutting tool. Instead, high pressured
air, water, highly focused laser, or other methods are used to remove material.
Benefits of Non-conventional Machining
1- Machining hard materials: Non-Conventional Machining can operate on hard brittle materials; these
materials can be hard or even impossible to machine using traditional methods.
2- Complex geometries: Non-conventional machining can create complex shapes as well as small
features.
3- Minimum tool wear: Due to non-conventional machining not using traditional cutting tools, it does
not require to be replaced due to wear, this saves on tool replacement cost.
4- Maintain material property: Non-conventional machining does not generate as much heat as
conventional machining this reduces the distortion that the material undergoes as well as maintain its
material properties even around the machined area.
Drawbacks of Non-conventional Machining
1- Slow Machining speed: Compared to traditional machining, non-conventional machining is slower at
carrying out simple machining processes.
2- High initial cost: The price to set up NCM equipment is higher than conventional machining
equipment, it is more difficult to set up and requires more space, which could prevent smaller
workshops from being able to use the equipment.
3- Environmental impact: Some NCM processes require special waste disposal, or it will impact the
environment negatively.
4- Operation difficulty: Operation NCM equipment requires trained professionals, which is not
necessary when operating traditional machining equipment.
Applications and Industries of Non-Conventional Machining
Owing to NCM’s ability to machine brittle material, and its dimensional accuracy, it is widely used
in different industries such as, Aerospace, Automotive and electronics industry. Intricate cooling channels
are machined into wind turbines using NCM. In automotive industry, NCM is used to machine lightweight
components which is achieved when specific materials are used, these materials are machined using NCM.
Examples of Non-Conventional Machining
Laser cutting
Laser cutting uses a highly focused laser beam, which is a monochromatic light beam, to remove
material from a workpiece. This creates a clean cut due to the material being vaporized or melted, this
depends on the power density of the laser, and the amount of time the laser interacts with the workpiece.
Laser beams power density can reach up to 106 (W/mm^2). This laser is focused on a small spot on the
workpiece, which heats that spot allowing the material to melt or vaporize. This happens when the power
density of the beam is larger than the power lost in conduction, convection, and radiation. Laser cutting
machines are usually computerized to allow for precise cutting paths, the laser usually removes a very thing
width from the material, which cuts the material.
Figure 22. Laser Cutting
Advantages
1- High precision: laser cutting has extremely high accuracy which is useful when creating intricate
shapes.
2- Material versatility: Laser cutting machine can operate on all materials.
3- Clean Cuts: laser cutting produces little to no burr, which is a lip of leftover material that appears
at the edge of the cut.
4- Fast cutting speed: Laser cutting is a fast process. The speed of the cut is dependent on the
thickness of the workpiece.
Disadvantages
1- Thickness limitations: Laser cutting is limited to specific thickness for the material.
2- Initial price: The price of a laser cutting machine is higher than traditional cutting methods.
3- Reflective materials: Laser cutting cannot be used on reflective materials such as glass, or
reflective metals.
4- Fume: Laser cutting process creates fumes which requires the room to be properly ventilated, and
a dust collection system must be set up.
Applications
Due to the high precision of laser cutting is used in the sheet metal industry, aerospace industry, and
electronic industry.
1- Cutting sheet metal parts for ducts
2- Circuit boards and stencils
3- Aircraft wing skin
Electrical Discharge Machining
EDM uses electrical sparks to erode material from the workpiece. Electrical sparks are created
between the electrode and the workpiece. When the spark is created heat is produced which melts of
vaporizes the material when contact is made this gradually removes material from the workpiece. Electrode
geometry affects the shape of the cut, different electrodes are used based on the complexity of the cut
needed. Dielectric fluid is used on the workpiece this acts as a coolant while removing any leftover material.
The EDM machine is controlled by a computer to change the position of the electrode (CNC).
Figure 23. Electrical Discharge Machining process.
Advantages
The EDM process has the same advantages as general non-conventional machining,
machining hard material, creating complex geometries, minimum tool wear, no heat produced.
Disadvantages
1- Slower machining time: EDM is a slower process compared to conventional machining.
2- High setup cost: Like most NCM, EDM has a high initial cost compared to traditional machining.
3- Surface Finish: EDM can sometimes achieve poor surface finishes.
4- Environmental Impact: EDM requires proper disposal if the dielectric fluid otherwise it will
impact the environment negatively.
Applications
EDM’s applications are the same as the general applications of the NCM.
Abrasive Water Jet Machining
Water jet machining is a process where water is used to accelerate abrasive particles which removes
material from the workpiece. A pump in the machine generates a highly pressurized water jet which mixes
with abrasive and then leaves through the nozzle and onto the workpiece. Water jet machining does not
require an abrasive to work however, adding the abrasive increases its efficiency ten times.
Figure 24. Abrasive Water Jet.
Advantages
The main advantage of water jet compared to other NCM is the low environmental impact as
it uses no harmful materials or coolants to do the cutting.
Disadvantages
However, waterjet cutting requires a large amount of water which could be a concern for
places with water scarcity. WJC also generates a lot of noise which requires proper ear protection.
Applications
An important application for AWJM is cutting concrete, stone, and other construction
materials.
Abrasive Jet Machining
Similarly to AWJM, AJM blasts abrasive at the workpiece this time using pressurized gas instead of
a water stream. The abrasive is usually AL2O3 or SiC. The nozzle has a small diameter of 0.3-0.5 mm. The
gas used should never be oxygen as it can react violently with the workpiece chips or the abrasive material.
Figure 25. Abrasive Jet.
Additive Manufacturing
Additive manufacturing, also known as 3D printing, is a type of manufacturing that builds the items
one layer at a time. Unlike machining methods that use subtractive manufacturing, this method adds layers
of material to achieve final product. It uses a wide variety of materials, and it turns Computer aided designs
(CAD) into a product. This is done by slicing the cad model into layers so it can be interpreted by the 3D
printer. Most 3D printed parts will require post processing, this could include curing the piece with a UV
(ultraviolet) light, machining the final product to remove supports, heat treating the piece, or shot peening
the product which is method to smooth out the rough surface.
Advantages
1- Combines benefits: additive manufacturing allows production to combine different materials which
allows the object manufactured to have an enhanced performance.
2- Weight reduction: Due to additive manufacturing’s ability to place materials only where it is
required, the weight of the final product is reduced, which increases efficiency.
3- Customization: Parts can be easily customized to any shape or size, If the design can be created on
CAD, a 3D printer can print it.
4- Material efficiency: Additive manufacturing does not produce as much waste as conventional
machining methods.
Disadvantages
1- Production speed: 3D printing is a slow manufacturing process compared to Traditional
manufacturing.
2- Material limitation: Materials that can be 3D printed are still limited and could be harder to find than
materials used in conventional manufacturing.
3- Post-processing: most 3d printed parts require postproduction machining to achieve the surface finish
required, it can also require the removal of 3d printed supports.
4- Cost: the cost per part produced can be high, especially for higher end 3D printing machines.
Applications
In the aerospace and automotive industry, additive manufacturing is used to make lightweight
structures that combine both strength and flexibility. In the biomedical industry, 3D printing can produce
custom implants that are personalized to each user. This is particularly useful in dental implants, as the
implant must match both the bone and soft tissue. 3D printing can also create products with thermal
resistance gradation, this means that the item is designed to make the parts more likely to experience
stronger heat more heat resistant than the rest of the part. Additive manufacturing is typically used for rapid
prototyping, direct part replacement, or producing new designs.
Examples
The additive manufacturing processes are classified into seven groups, Photopolymerization (VPP),
material jetting (MJT), material extrusion (MEX), sheet lamination, powder bed fusion (PBF), binder jetting
(BJ), and DED.
Stereolithography
Stereolithography or SLA is a VPP method. This method is characterized by a vat of liquid which is
selectively cured by light-activated polymerization. This is done by a UV laser, and mirrors on the x-y axis
controlled by a computer used to direct the laser so it can cure the top surface of the resin in the vat. There
are many different types of resin that can be used in this process allowing for different material properties
such as strength, flexibility, high temperature resistance or biocompatibility.
Figure 26. SLA manufacturing.
Advantages
1- High accuracy and surface finish
2- Large object size
3- Isotropic final product: this offers good resistance to directional forces.
Disadvantages
1- Postprocessing: removing supports is time consuming.
2- Post-curing: Curing the final product is mandatory for SLA.
3- Limited materials
4- Removing the piece from the build plate can ruin the printed part.
3D Inkjet
3D inkjet is a type of MJT, it uses droplets of fluid which is selectively dropped onto the build plate
to build up material and create a final 3D printed product. Inkjet heats the resin which turns is from high
viscosity into lower viscosity liquid, which allows it to flow through the pin heads. UV light is then passed
on the droplets which cures them.
Figure 27. 3D Inkjet.
Advantages
1- soluble supports available: this allows for easy support removal.
2- Can blend photocurable resins which create digital materials.
3- Ability to mix different colors and materials.
Drawbacks
1- Expensive materials
2- The final product degrades over time due to heat and sunlight.
Applications
1- sophisticated prototypes
2- biomedical models
3- investment casting prototypes
4- electronic components
5- 4D printing allows product transformation over time.
Fused Filament Fabrication
FFF stands for fused filament fabrication, it is a part of MEX technology, and it is defined as a
manufacturing process in which material is dispensed through a nozzle or orifice.
Figure 28. Fused Filament Fabrication.
Advantages
1- Low cost
2- Straightforward process
3- Easy to set up as it only requires a computer, material, and electricity.
4- Widely available
Disadvantages
1- Low accuracy cannot get high detail in final product.
2- Rough surface finish
3- Weak mechanical properties
4- Postprocessing is required.
Applications
1- Food printing
2- Architectural models
Parts Design
Shaft Collar
A shaft collar is a cylindrical ring used to provide stability for components on a rotating shaft. It is a
cylinder with a centrale bore. The size of the bore is dependent on the size of the shaft the collar attaches to.
Figure 29. Shaft Collar.
This particular shaft collar has an outer diameter of 20mm (+/- 0.1mm), an inner diameter of
15mm (+/-0.05mm), width of the collar is 10mm (+/-0.2mm), and the screw used is an M4 x0.7. This collar
is made from 300 stainless steel, this is a commonly used material due to its high strength, and ease of
machinability.
The outer diameter and the bore of the collar is created by turning. This is due to turning’s
ability to create precise and accurate cylindrical shapes which is important since this part will be attached to
a rotating shaft. A chamfering tool is attached to the turning machine to create the chamfer on the collar. The
setscrew hole is made through drilling, this can create the threaded hole for a setscrew to secure it into place.
Conventional machining is suitable for this product due to its precision and its ability to
achieve the required tolerance. The material is also suitable for conventional machining as it has high
strength but is not brittle.
Advantages of using these methods is that they are straight forward and can achieve required
tolerance, however the waste generated during this process will need to be recycles which is not cost
efficient.
Custom Denture Retainer
This is a transparent dental appliance used by patients to prevent minor shifting of teeth. This
part is custom made for the patient however it is a simple U-shape that can go over the patients’ teeth, the
design of it can change from one person to another based on their needs.
Figure 30. Custom Denture Retainer.
The inner dimension is based on the user’s dental arch. These dimensions are taken from the
patient using digital 3D scans. This ensures a precise and comfortable fitting. The tolerance of this fit is ±
0.3 mm. The dentures are 1.5mm thick, this thickness is maintained all around the denture.
The denture is made from a biocompatible resin, this is created specifically for dental applications, it
needs to have a high enough strength to withstand consistent use, it must be light to prevent discomfort, and
needs to be resistant to staining from food.
3D printing specifically stereolithography (SLA) is used, this is due to the dentures need to be a
custom fit for the user. SLA also produces high resolutions parts that can be made from clear resin making
them unnoticeable while in use. However, this material is less durable than traditional retainers, so they may
require potential replacements over time.
Table of Contributions
Name
ID
Parts Done
Mayar Ayman
234643
Casting Process
Malak Ahmed
232635
Comparing between different Welding Specimens
Aya Tarek
233799
Machining Process
Mark Samer
229246
Comparing between Sand and Die Casting
Peter Nabil
236714
Welding Process
References
Davoudinejad, Ali & Perez, L. & Quagliotti, Danilo & Pedersen, David & Albajez, Jose & Yagüe-Fabra, José
& Tosello, Guido. (2019). Geometrical and feature of size design effect on direct stereolithography micro
additively manufactured components. European Structural Integrity Society. 13. 1250-1255.
10.1016/j.prostr.2018.12.256.
Ian Gibson, David Rosen and Brent Stucker, “Additive Manufacturing Technologies: 3D Printing, Rapid
Prototyping, and Direct Digital Manufacturing” 2nd edition, Springer, ISBN: 9781493944552 (2016)
Hassan Abdel-Gawad El-Hofy, Fundamentals of Machining Processes Conventional and Nonconventional
Processes, Third Edition, Routledge Taylor and Francis 2019
M. P. Groover, “Fundamentals of Modern Manufacturing: Materials, Processes, and Systems”, 4th Edition,
ISBN 978-0470-467002