Comparative Study On Subtractive And Additive

Manufacturing

SM process:
There are following some common process of
Subtractive manufacturing ;

1. Cutting:
Material is cut away to create a product or
component. Cutting involves the removal of material in order
to create a product. This can involve saws, scissors, blades, or
CNC machines.

2. Turning:
Turning is a subtractive machining process that uses a
cutting tool, typically a lathe, to achieve a variety of shapes for
end use plastic, metal, wood, or stone parts.

3. Milling:
Milling is a subtractive machining process that uses a
wide range of machine toolsets to efficiently precision-cut a
variety of materials (such as metals, plastics, or wood) into a
defined geometrical part.

4. Boring:
Boring is a subtractive manufacturing technique used
to enlarge a pre-drilled or casted hole yet enhance its
dimensional accuracy.

AM Process:

Binder Jetting:
Binder jetting, also known as material jetting or inkjet powder
printing, is among the most common additive manufacturing
types.

2.Directed energy deposition:

Directed energy deposition (DED) utilizes
welding principles to create three-dimensional objects. The
material - typically metal wire or powder - is melted by a
focused energy source like a laser or electron beam.

3. Material Extrusion:
Material extrusion works similarly to a hot
glue gun. The material feeds into the printer from a coil. The tip
of the nozzle heats and melts the material. The liquid material
is then placed layer by layer on the build platform, where it can
cool and solidify, forming the object.
4. Powder bed fusion:
Powder bed fusion, otherwise known as
electron beam melting (EBM), starts with a large bed of
powdered material, typically plastic, metal, sand, or ceramic
powders mixed with sand.

5. Sheet lamination:
Sheet lamination, otherwise known as ultrasonic
additive manufacturing (UAM) or laminated object
manufacturing (LOM) - is an additive manufacturing process
that stacks thin sheets of material and bonds them together
through ultrasonic welding, bonding, or brazing. As the layers
stack up, the object takes shape.

6.Vat Polymerization:
Vat polymerization is similar to powder bed fusion, except
instead of a bed of powder, it uses a vat of photopolymer resin,
which is hardened in layers by an ultraviolet laser. Once a layer
is complete, more resin is added, and the next layer gets built.
This process continues until the object is complete.

7. Material Jetting:
Similar to binder jetting, material jetting layers
material to construct an object. However, instead of layering
adhesive on a bed of powder, material jetting melts wax-like
materials and precisely deposits droplets onto the build
platform. As the layers build up, the object takes shape.

Difference between SM and AM:

Subtractive manufacturing is an umbrella term
for various controlled machining and material removal
processes that start with solid blocks, bars, rods of plastic,
metal, or other materials that are shaped by removing material
through cutting, boring, drilling, and grinding.And in contrast to
the subtractive process of removing material from a larger
piece, additive manufacturing or 3D printing processes build
objects by adding material one layer at a time, with each
successive layer bonding to the preceding layer until the part is
complete.

Advantages of AM:
 The Cost Of Entry Continues to Fall.

 You'll Save on Material Waste and Energy.

 Prototyping Costs Much Less.

 Small Production Runs Often Prove Faster and Less

Expensive.

 You Don't Need as Much On-Hand Inventory.

 It's Easier to Recreate and Optimize Legacy Parts.

Advantages of SM:
 Wide variety of materials can be processed.

 Large size objects can be fabricated.

 Processes are faster.

Limitations of AM:
That is largely because AM still has slow build
rates and doesn't provide an efficient way to scale operations
to produce a high volume of parts. Depending on the final
product sought, additive manufacturing may take up to 3 hours
to produce a shape that a traditional process could create in
seconds.

Limitations of SM:
There is material wastage as the chips
formed are wasted. Even if the chips can be recycled, they are
still waste material. It takes more time per part than additive
and formative manufacturing methods.

Application of AM:

 Aerospace Industry & Suppliers

 Automotive Industry & Suppliers
 Machinery (e.g. Turbines, Special Machinery)
 Medical implants (Dental, Orthopedic)
 Handling and Robotics
 Lifestyle & Sports (e.g. Jewelry, Biking)
 Custom Parts (e.g. Classic Car Parts, Surgical Tools).
Application of SM:

Subtractive manufacturing processes are typically used

to create parts in plastics or metals for prototyping,
manufacturing tooling, and end-use parts. They're ideal for
applications that require tight tolerances and geometries that
are difficult to mold, cast, or produce with other traditional
manufacturing methods.

Examples of AM:

1. Sharonville Transmission Plant

2. Fortify
3. Precision Metal Products
4. Guhring: Cutting Tool
5. Lincoln Electric Additive Solutions

Examples of SM:

1.Lathe-turning
2.Milling
3. Drilling
4.Sawing
5.Thread-cutting
6.Gear-cutting

Review:

In recent days, additive manufacturing (AM) plays a vital role in

manufacturing a component compared to subtractive
manufacturing. AM has a wide advantage in producing complex
parts and revolutionizing logistics panorama worldwide. Many
researchers compared this emerging manufacturing
methodology with the conventional methodology and found
that it helps in meeting the demand, designing highly complex
components and reducing wastage of materials and there are a
wide variety of AM processes.