Presentation on

ADVANCES IN MANUFACTURING
AND JOINING TECHNIQUES
Under the guidance of
Dr. Manoranjan Kumar Manoj

Submitted by –
Shivam Chandrakar (19121065), Surendra Patro (19121073),
Karan Garg (19121027), Saurabh Pandey (19120912)
 Contents
 Unconventional machining processes
 Additive manufacturing
 Glass science
 Composite
 Conclusion for manufacturing methods
 History and advances
 Materials used in automobiles
 Methods used in construction of vehicles
 Rivets in automotive industry
 Resistance spot welding
 Need of advance joining techniques
 Comparison of various joining methods
 Clinching
 Conclusion for joining methods
Advanced manufacturing techniques
 Unconventional
Machining Processes

 Additive Manufacturing

 Glass Science

 Composite Materials
 Need for unconventional processes
Intricate shaped blind square hole of 15mm x 15mm with a depth of 30 mm
with a tolerance of 100 microns.

Difficult to machine material – e.g., Inconel, Ti-alloys or carbides, ceramics,

composites etc.

Deep hole with small hole diameter – e.g., 1.5mm hole with l/d = 20.

Machining of composites.

When the shape of the part is too complex.

Non-traditional manufacturing processes is defined as a group of processes that

remove excess material by various techniques involving mechanical, thermal, electrical
or chemical energy or combinations of these energies. They do not use a sharp cutting
tools.
 Classification of Advanced Machining
Techniques

Electro- Electro-
Mechanical Chemical
chemical thermal
Processes Processes
Processes processes

 AJM
 EDM
 USM  ECM
 LJM  CHM
 WJM  ECG
 EBM  PCM
 AWJM  EJD
 PAM
 AFM
 MAF
 Process selection
Physical parameters – voltage, current, power, work material

Shapes to be machined – small holes, deep holes, finishing, threading

Process capabilities – tolerance, surface finish, metal removal rate

Economic consideration – capital cost, tooling cost

 Additive Manufacturing
It refers to the layer-by-layer fabrication of 3D physical models directly from
CAD.
It is an automatic process of manufacturing objects (parts, prototypes, tools
and even assemblies) directly from their CAD models without any cutters,
tool or fixtures specific to the object geometry.
 Generic method of additive
manufacturing
Preparation of CAD file Generation of stl file Stl file manipulation

Generation of support
structure and selection
of build orientation

Remove part & support Produce physical Slicing stl file to form
structure objects layers

Post processing
 Classification of AM
Vat photo-polymerization

Material jetting
Low energy consumption

Binder jetting

Material extrusion

Sheet lamination

High energy consumption

Powder bed fusion

Direct energy deposition

 Glass
Glass is an amorphous solid.

It is a non-crystalline.

It is most often formed by rapid cooling (quenching) from molten form.

Archaeological evidence suggests glass-making dates back at least 3,600 BC in

Mesopotamia, Egypt or Syria.
https://www.nde-ed.org/Physics/Materials/Structure/solidstate.xhtml
 Composition of glass

Raw materials

Sodium as Na_2CO_3 (used in soft glass)

Potassium as K_2CO_3 (used in hard glass)
Calcium as limestone, chalk and lime
Lead as litharge, red lead (flint glass)
Silica as quartz, white sand and ignited flint
Zinc as zinc oxide (heat and shock proof glass)
Borates as borax, boric acid (heat and shock
proof glass)
Cullets or pieces of broken glass to increase
fusibility
 Toughening of glass

Physical method Chemical method

Tempering Ion-exchange
 Tempering vs Ion-exchange

Tempering Ion-exchange

Compressive stress Less More

Cost Low Higher

Thin glass Not recommended Recommended

 Composite materials
Composite: A man-made multiphase material

Two-phase composite

Continuous phase Discontinuous phase

(matrix) (reinforcement)
Classification of composites based on the
nature of matrix

Polymer matrix composite - GFRP, CFRP

Metal matrix composite - Al−Al2O3

Ceramic matrix composite - Al2O3−SiC

Application of MMC in automotive
industries
Some engine components have been introduced consisting of an aluminium-
alloy matrix that is reinforced with aluminium oxide and carbon fibers.

This MMC is light in weight and resists wear and thermal distortion.

MMC are also employed in driveshafts (that have higher rotational speeds
and reduced vibrational noise levels), forged suspension and transmission
components.
Advances in joining techniques
 History and advances
 In the early days of the auto industry, different materials
such as metals and wood were used.

 These were joined usually mainly by manual processes

such as solid riveting and screwing.

 Later, vehicle generations were exclusively steel-based

and mechanical joining methods were replaced by
highly productive welding processes.

 Driven by the trend to utilize aluminum and other non-

iron materials in car bodies, several innovations in the
field of mechanical joining technologies were made
during the last three decades
Materials used in automobiles
Methods used in construction of vehicle
Rivets in automotive industry
EXPLANATION, TYPES, ADVANTAGES & DISADVANTAGES
What are rivets ?
 Rivets are a common fastening method used in the automotive industry to
join two or more components together.
 They are popular because they are strong, durable, and easy to install, and
can be used in a variety of applications, from structural joints to aesthetic
accents.
 Rivets can be made from a range of materials, including steel, aluminum,
and titanium, depending on the requirements of the application.
 They come in various sizes and shapes, and different types of rivets are used
for different applications.
 Rivets consist of a head and a shank, which is inserted into a pre-drilled hole
in the components being joined.
 The shank is then deformed, either by squeezing or pulling, to create a
secure joint. This deformation process creates a tight grip on the materials
being joined, providing a strong and reliable bond.
Types of rivets used in automotive industry
There are several types of rivets used in the automotive industry, each with their own
unique characteristics and applications. Here are some of the most common types of
rivets used:
 Solid Rivets: Solid rivets are one of the oldest and most reliable types of rivets used in
the automotive industry. They are made from a single piece of material and require a
rivet gun to install. Solid rivets are ideal for use in structural applications, such as
joining metal sheets together.
 Blind Rivets: Blind rivets are also known as "pop" rivets. They are used when only one
side of the material is accessible and are installed from one side only. Blind rivets
consist of a mandrel and a sleeve that is pulled through the material being joined,
creating a strong and reliable joint. They are ideal for use in applications where the
rear side of the material is inaccessible, such as in the interior of a vehicle.
 Structural Rivets: Structural rivets are designed to provide high-strength and are often
used in applications where the joint is under high stress. They are usually made of
steel and require a special tool for installation. Structural rivets are commonly used in
the automotive industry for joining structural components such as chassis frames,
suspension parts, and body panels.
Types of rivets used in automotive
industry

Solid, blind and structural rivets

Types of rivets used in automotive industry
 Exploding Rivets: Exploding rivets, also known as "bulb-tite" rivets, are used
for joining thin sheet metal components. The rivet is inserted into a pre-
drilled hole and then pulled tight with a special tool, causing the rivet to
"explode" and create a secure joint.

 Huck Bolts: Huck bolts are a type of blind rivet that is threaded on the
mandrel end. They are used in applications where a high level of strength
and reliability is required. Huck bolts are commonly used in the automotive
industry for joining heavy-duty components such as suspension
components and frames.

 Peel Rivets: Peel rivets are used for joining soft materials such as plastic or
rubber to metal components. They are inserted into a pre-drilled hole and
then expanded to create a secure joint. Peel rivets are commonly used in
the automotive industry for joining interior trim panels and other soft
components to metal frames or supports.
Types of rivets used in automotive
industry

Exploding, huck bolt and peel rivets

 Advantages & disadvantages of rivets in automotive
industry
Advantages-
1. Strong and Durable: Rivets are a very strong and durable fastening method, making them ideal for use in
the automotive industry where high levels of strength and durability are required.
2. Quick and Easy to Install: Rivets can be installed quickly and easily with simple hand tools or automated
riveting machines, making them a popular choice for automotive manufacturers who need to maintain
high production rates.
3. Cost-Effective: Rivets are often less expensive than other fastening methods, such as welding or
screwing, making them a cost-effective option for automotive manufacturers.
4. Vibration Resistant: Rivets can resist vibration and prevent components from loosening or becoming
detached, which is particularly important in the automotive industry where components are subject to
high levels of vibration.
5. Aesthetic Appeal: Rivets can be used for aesthetic purposes, giving automotive components a unique and
attractive appearance that can be customized to suit the individual needs of the manufacturer.
6. Corrosion Resistant: Rivets made from corrosion-resistant materials can be used in harsh environments,
such as those found in the automotive industry, to prevent rust and other forms of corrosion.
Disadvantages-

1. Limited Disassembly: Rivets are a permanent fastening method, meaning that they cannot be
easily disassembled once they have been installed, which can make repair or maintenance of
certain components difficult.

2. Reduced Structural Integrity: While rivets can be strong and durable, they may not provide
the same level of structural integrity as other fastening methods, such as welding or bolting.

3. Noise and Vibration: Rivets can produce noise and vibration during installation and use,
which can be a concern for automotive manufacturers looking to reduce noise and vibration
levels in their products.

4. Limited Joining Options: Rivets are typically only suitable for joining materials of similar
thicknesses, which can limit their application in the automotive industry where materials of
varying thicknesses are often used.

5. Surface Damage: The installation of rivets can sometimes cause surface damage, such as
dents or scratches, to the materials being joined, which can be a concern for automotive
manufacturers looking to maintain a high level of finish on their products.
 Resistance Spot Welding (RSW)
Resistance spot welding is a process of joining two or more metal sheets or parts
together by applying pressure and an electric current. The process involves clamping
the metal parts between two electrodes, typically made of copper, and then passing an
electric current through them.

The resistance of the metal to the electric current generates heat, which causes the
metal to melt and form a weld. The amount of heat generated is controlled by the
current, the duration of the current, and the pressure applied by the electrodes.

The electrodes typically have a pointed or flat tip to concentrate the current flow
and ensure a strong weld. The process is commonly used in the automotive industry
for welding sheet metal parts, as well as in the manufacturing of appliances,
electronic devices, and other metal products.

Resistance spot welding offers several advantages over other welding methods,
including speed, precision, and the ability to weld a variety of metal types and
thicknesses. However, it does have some limitations, such as difficulty in welding
thicker materials and the need for access to both sides of the joint.
 Advantages of RSW
Resistance spot welding has several advantages, including:
1. Speed: Resistance spot welding is a fast process, with welds typically completed in a fraction
of a second. This makes it an efficient method for high-volume production.
2. Precision: The process is highly controllable, allowing for precise placement and size of the
weld. This makes it suitable for applications where a high degree of accuracy is required.
3. Strong joints: Resistance spot welding produces strong, reliable joints that are typically as
strong or stronger than the base metal. This is because the process uses high pressure and high
heat to create a metallurgical bond between the metal parts.
4. Versatility: Resistance spot welding can be used to weld a variety of metals, including steel,
stainless steel, aluminum, and copper. It is also suitable for welding different thicknesses of
metal.
5. Efficiency: Resistance spot welding requires minimal preparation, with no need for filler
materials or flux. It also produces minimal waste, as there are no consumable materials used
in the process.
6. Safety: Resistance spot welding is a safe process, with no harmful fumes or gases produced.
The electrodes used in the process also have a low risk of causing electrical shock or injury.
 Disadvantages of RSW
While resistance spot welding has many advantages, it also has some limitations and disadvantages,
including:
1. Limited joint access: Resistance spot welding requires access to both sides of the joint, which can
be difficult or impossible for some applications. This can limit the use of the process in certain
types of assemblies.
2. Difficulty with thicker materials: Resistance spot welding is more difficult with thicker materials,
as it requires more heat and pressure to create a strong weld. This can limit its use in applications
that require thick materials.
3. Equipment cost: Resistance spot welding equipment can be expensive to purchase and maintain,
which can make it less cost-effective for smaller production runs.
4. Operator skill: Resistance spot welding requires skilled operators who understand how to control
the heat and pressure to create a strong weld. This can require additional training and expertise.
5. Environmental concerns: Resistance spot welding can produce high levels of noise and require
large amounts of electricity, which can contribute to environmental concerns in some settings.
6. Maintenance: The electrodes used in resistance spot welding wear out over time and need to be
replaced regularly, which can add to the cost and time required for maintenance.

Overall, resistance spot welding is a reliable, efficient, and versatile method of joining metals that is
widely used in a variety of industries.
Need of advance joining techniques
 The most used method for joining the steel sheets is the resistance
spot welding. But most of steel sheets are galvanized to improve
life of car body.

 Considering most of steel sheets are galvanized to improve life of

car body, the wear of welding electrode decreases due to the lower
electrical resistance and melting temperature of the coating layer.
Therefore, alternative joining methods have attracted increasing
interest and applications.

 The demands for higher fuel efficiency in the automotive

sector have motivated the increased use of multi-material
combinations for lightweight designs in recent years.

 This has inevitably led to challenges in joining materials

where aluminum alloys, magnesium alloys, and steels (i.e. low,
medium and ultra-high strength) are combined.
Need of advance joining techniques
 The most used method for joining the steel sheets is the resistance
spot welding. But most of steel sheets are galvanized to improve
life of car body.

 Considering most of steel sheets are galvanized to improve life of

car body, the wear of welding electrode decreases due to the lower
electrical resistance and melting temperature of the coating layer.
Therefore, alternative joining methods have attracted increasing
interest and applications.

 Although the dominant welding method for joining steel car bodies
is resistance spot welding (RSW), it does not necessarily produce a
robust joint to weld aluminum to steel. This is mainly attributed to
the poor performance of the weld because of the formation of a
thick intermetallic compound (IMC) reaction layer between the
aluminum and steel during resistance spot welding.
Need of advance joining techniques
 The demands for higher fuel efficiency in the automotive
sector have motivated the increased use of multi-material
combinations for lightweight designs in recent years.

 This has inevitably led to challenges in joining materials

where aluminum alloys, magnesium alloys, and steels (i.e. low,
medium and ultra-high strength) are combined.

 This has inevitably led to challenges in joining materials

where aluminum alloys, magnesium alloys, and steels (i.e. low,
medium and ultra-high strength) are combined.

 Welding aluminum and steel components together is easier said

than done. That’s because aluminum has much different properties
than steel.

 The melting temperature of aluminum is approximately 650 C vs.

1,538 C for steel. This means aluminum joints will melt and flow
away before a steel joint has melted.
Need of advance joining techniques
 Another issue when joining dissimilar materials is galvanic
corrosion. Dissimilar electrically conductive materials have different
electrode potential. When they come into contact with an
electrolyte, one material can act as an anode and the other as a
cathode. This results in one of the metals corroding preferentially
to the other.
Comparison of various joining methods
 Clinching
 Clinching is a joining method in which sheet metal parts are
deformed locally without the use of any additional elements.

 The technology allows joining of two or more metal sheets without

any edge preparation as well as when the clinched joint has been
made, there is no need for repainting the sheets or performing
stress relieving treatments.

 Clinch riveting is a high-speed joining process that does not require

pre-existing holes, therefore eradicating the need to align the
joining materials.

 The punch impacts the top sheet, and partially piercing the bottom
one. The die on the underside of the materials causes the rivet to
flare under the force, creating a mechanical interlock
 Conclusion for joining methods
The increasing use of coated, lightweight and high-strength materials has led the
automotive industry to re-examine traditional methods of component assembly.
Conventional materials are in the limit of use, despite of the continual increasing
of their technological application. It is necessary to develop and evaluate new
material combinations and progressive technologies of their processing to
withstand demanding conditions together with the economical demanding. The
question is not only how to make the parts of car body, but also how to join
them together in functional and safety construction. The results of experiments
showed possibility of mechanical joining such as clinching and clinch riveting to
be an alternative method to resistance spot welding when joining the car body
steel sheets. The joints formed by method of clinching as well as clinch riveting
do not reach the values of load-bearing capacity of resistance spot welded
joints, however. Their utilizing in automotive industry is for their advantages
such as low energy consumption during joining, retained corrosion resistance of
joined galvanized materials, or the possibility to combine different materials in
terms of quality, thicknesses, as well as ferrous and non-ferrous metals.
Thank you !