Name: - DHRUV SINGHAL (2K20/PE/25)

Precision Manufacturing
ASSIGNMENT NO.: - 4

Q-1. Discuss Precision, Accuracy, smoothness with examples and

requirements. Elaborate High precision and ultra precision machining.

Ans-
Precision, accuracy, and smoothness are crucial factors in machining to achieve high-quality
parts that meet stringent specifications. High precision and ultra-precision machining are
advanced forms of machining that require even tighter tolerances and finer surface finishes.
Let's discuss each concept in detail, along with examples and requirements, and then
elaborate on high precision and ultra-precision machining with diagrams.

1. Precision: Precision refers to the consistency and repeatability in producing parts with
tight tolerances. High precision machining involves achieving extremely accurate and
consistent results, often with tolerances in the micrometer or sub-micrometer range.
Examples of high precision machining include producing components for aerospace,
medical, and optical industries, where tight tolerances are critical for the parts to function
properly.

Requirements for High Precision Machining:

- High-quality machine tools with low runout, thermal stability, and minimal vibration levels to
minimize dimensional variations.
- Advanced measuring instruments with high accuracy and resolution for precise
measurements.
- Skilled operators with extensive experience and expertise in using precision tools and
measuring instruments.
- Strict control over environmental factors, such as temperature, humidity, and vibrations, to
minimize their impact on machining accuracy.
- Specialized cutting tools with high wear resistance, sharp edges, and precise geometries to
achieve tight tolerances.

2. Accuracy: Accuracy refers to achieving close conformity between the actual dimensions
of the machined part and the desired specifications. Ultra-precision machining takes
accuracy to an even higher level, often producing parts with sub-micrometer tolerances.
Examples of ultra-precision machining include manufacturing precision optics,
semiconductors, and microelectromechanical systems (MEMS), where even minor
dimensional variations can result in functional failure.

Requirements for Ultra-Precision Machining:

- Ultra-precision machine tools with exceptional stability, low thermal deformation, and
ultra-precise motion control to achieve nanometer-level accuracy.
- Metrology instruments with extremely high accuracy and resolution for precise
measurements at sub-micrometer or nanometer scale.
- Expert operators with extensive knowledge and skills in ultra-precision machining
techniques, including single-point diamond turning, micro-milling, and micro-grinding.
- Controlled environment with minimal temperature fluctuations, low vibration levels, and
minimal airborne particles to ensure ultra-high accuracy.
- Specialized cutting tools with ultra-precise geometries, edge sharpness, and minimal
runout for achieving sub-micrometer tolerances.

3. Smoothness: Smoothness, or surface finish, is critical in applications where the surface

quality of the machined part affects its performance or aesthetics. High precision and
ultra-precision machining often requires extremely smooth surfaces with low roughness
values to meet the stringent requirements of industries such as optics, electronics, and
medical implants.

Requirements for Achieving Smoothness:

- Specialized cutting tools with ultra-sharp edges, precise geometries, and minimal runout to
minimize surface defects, such as burrs, scratches, and tool marks.
- Controlled cutting parameters, such as cutting speed, feed rate, and depth of cut, to
achieve desired surface roughness.
- Use of advanced cutting fluids and lubrication techniques to reduce friction and heat
generation during machining, which can affect surface quality.
- Rigorous inspection and measurement of surface roughness using high-precision surface
profilometers or atomic force microscopes to ensure compliance with stringent smoothness
specifications.

In conclusion, precision, accuracy, and smoothness are critical aspects of machining that are
essential in producing high-quality parts that meet the desired specifications. High precision
and ultra-precision machining are advanced forms of machining that require specialized
equipment, cutting tools, skilled operators, and controlled environments to achieve extremely
tight tolerances, high accuracy, and fine surface finishes. Diagrams illustrating the various
factors and requirements for precision, accuracy, and smoothness in machining can provide
a visual representation of these concepts.

Q-2. Discuss hydrostatic, hydrodynamic, hybrid fluid, Aerostatic, Aerodynamic

bearings. Hybrid gas bearings with examples.
Ans-

Hydrostatic Bearings: Hydrostatic bearings use a thin film of fluid, typically a liquid, to
separate the bearing surfaces and provide a low-friction interface. The fluid is pressurized,
usually by an external source, to create a pressure barrier that lifts and separates the
moving parts of the bearing. This results in reduced friction and wear. Hydrostatic bearings
are commonly used in high-precision applications where low friction, high load capacity, and
precise positioning are required. Examples of hydrostatic bearings include air bearings used
in ultra-precision machine tools and hydrostatic journal bearings used in large turbines.

Hydrodynamic Bearings: Hydrodynamic bearings rely on the relative motion between the
bearing surfaces to generate a hydrodynamic film of lubricating fluid that supports the load
and separates the surfaces. As the bearing rotates, the fluid is drawn into the gap between
the surfaces, forming a pressurized wedge that lifts and separates the moving parts.
Hydrodynamic bearings are widely used in various applications, such as automotive
engines, industrial machinery, and pumps.

Hybrid Fluid Bearings: Hybrid fluid bearings combine the principles of hydrostatic and
hydrodynamic bearings. They use a combination of externally pressurized fluid and relative
motion between the surfaces to create a fluid film that supports the load. Hybrid fluid
bearings are typically used in applications where high load capacity, high stiffness, and high
damping are required. Examples of hybrid fluid bearings include tilting pad journal bearings
used in large rotating machinery and certain types of high-performance gas bearings.

Aerostatic Bearings: Aerostatic bearings use a gas, typically air, to separate the bearing
surfaces. The gas is supplied at high pressure, creating a cushion of air that lifts and
supports the moving parts. Aerostatic bearings are used in applications where extremely low
friction, high precision, and high load capacity are required. Examples of aerostatic bearings
include air bearings used in precision measuring instruments, semiconductor manufacturing
equipment, and aerospace applications.

Aerodynamic Bearings: Aerodynamic bearings use the principles of fluid dynamics to

create a pressurized film of gas that supports the load. The gas is typically supplied through
a rotating or stationary groove in the bearing surface, creating a pressure barrier that lifts
and separates the moving parts. Aerodynamic bearings are commonly used in high-speed
rotating machinery, such as turbochargers, where low friction and high stability are essential.

Hybrid Gas Bearings: Hybrid gas bearings combine the principles of aerostatic and
aerodynamic bearings. They use a combination of externally supplied gas and
self-generated gas film to create a bearing interface. Hybrid gas bearings are used in
applications where high-speed, high-temperature, and high-precision operation are required.
Examples of hybrid gas bearings include gas foil journal bearings used in high-speed
turbomachinery and certain types of gas-lubricated thrust bearings.

In summary, bearings can be categorized into various types based on their operating
principles, including hydrostatic, hydrodynamic, hybrid fluid, aerostatic, aerodynamic, and
hybrid gas bearings. Each type of bearing has its own advantages and is suitable for specific
applications depending on factors such as load capacity, friction, precision, speed, and
temperature requirements.

Q-3 Describe sources/types of errors in Precision Manufacturing and how to control

the same.

Ans-
Precision manufacturing processes require tight tolerances and high accuracy to produce
parts with precise dimensions and specifications. However, there are several sources/types
of errors that can occur during precision manufacturing, which can result in deviations from
the desired specifications. Here are some common sources/types of errors in precision
manufacturing:

Machine Tool Errors: Machine tool errors can arise from various factors such as geometric
errors in the machine structure, thermal expansion of the machine components, backlash in
mechanical components, and wear and tear of machine components. These errors can
cause deviations in the dimensions, form, and surface finish of the manufactured parts.
Control measures: Regular calibration and maintenance of machine tools, use of precision
machine tools with low geometric errors, temperature compensation techniques, and using
anti-backlash mechanisms can help control machine tool errors.

Tooling Errors: Tooling errors can occur due to wear and tear of cutting tools, inaccuracies
in tool geometry, and variations in tool material properties. These errors can affect the
surface finish, dimensional accuracy, and form of the machined parts.
Control measures: Regular inspection and replacement of cutting tools, use of high-quality
tooling materials, and precise tool geometries can help control tooling errors. Additionally,
using tool wear monitoring systems and adaptive control techniques can also help
compensate for tooling errors.

Material Variability: Variations in material properties, such as dimensional changes due to

temperature fluctuations, inconsistencies in material composition, and material defects, can
lead to deviations in the final product dimensions and properties.
Control measures: Use of high-quality materials with consistent properties, proper material
handling and storage practices, and implementing material inspection and testing techniques
can help control material variability.

Metrology Errors: Metrology errors can arise from inaccuracies in the measurement
equipment, measurement techniques, and operator errors. These errors can affect the
accuracy of the measured dimensions and specifications, leading to deviations in the
manufactured parts.
Control measures: Calibration and regular maintenance of measurement equipment, use of
accurate measurement techniques, proper training and qualification of operators, and
implementing statistical process control (SPC) methods can help control metrology errors.

Process Variability: Variations in process parameters, such as cutting speed, feed rate,
coolant flow rate, and machining conditions, can result in dimensional inaccuracies, surface
finish variations, and other deviations in the manufactured parts.
Control measures: Strict process control and monitoring, use of process parameter
optimization techniques, implementing process monitoring and feedback systems, and
utilizing advanced process control techniques can help control process variability.

Human Errors: Human errors, such as programming mistakes, setup errors, and operator
mistakes, can result in deviations in the manufactured parts.
Control measures: Proper training and qualification of operators, thorough process
documentation, implementation of standard operating procedures (SOPs), and use of
error-proofing techniques, such as mistake-proofing (poka-yoke), can help control human
errors.

In conclusion, precision manufacturing processes are susceptible to various sources/types of

errors that can result in deviations from the desired specifications. Implementing proper
control measures, such as regular calibration and maintenance of machines and
measurement equipment, use of high-quality materials and tooling, process control and
monitoring, and operator training and qualification, can help control these errors and improve
the overall precision and quality of manufactured parts.

Q-4 Describe Micro machining, LBM, EBM USM, LJM, EDM, Silicon micro machining
, Wet & Dry machining all with Schematic diagrams, Advantages/Disadvantages,
Applications...Also role of CAM, AI, IOT,5G etc. in these processes.

Ans-

1. Micro Machining: Micro machining is a process that involves manufacturing small-sized

components with high precision using conventional or non-conventional machining
techniques. It is typically used in applications where miniaturization is required, such as in
electronics, medical devices, and aerospace.

Advantages: High precision, ability to fabricate complex shapes, and suitability for
small-scale production.

Disadvantages: Limited material removal rate, challenges in tooling and fixturing for small
components, and high costs of equipment.

Applications: Electronics (microelectronics, micro-electromechanical systems or MEMS),

medical devices (implants, sensors), aerospace (miniature components for satellites and
aircraft), and automotive (fuel injectors, sensors).

2. Laser Beam Machining (LBM): LBM is a non-conventional machining process that uses
a high-energy laser beam to remove material from a workpiece. It is commonly used for
cutting, drilling, and surface modification of materials.

Advantages of LBM:
- High precision and accuracy
- Non-contact process, no tool wear
- Minimal heat affected zone
- Suitable for a wide range of materials
- Can achieve complex geometries

Disadvantages of LBM:
- Limited material removal rate
- High cost of laser equipment
- Safety concerns due to laser radiation
- Limited depth of cut

Applications of LBM:
- Microelectronics and semiconductor fabrication
- Medical devices manufacturing
- Aerospace and automotive industries
- Jewelry and watchmaking.
3. Electron Beam Machining (EBM): EBM is a non-conventional machining process that
uses a high-velocity electron beam to remove material from a workpiece. It is commonly
used for drilling, cutting, and welding of materials.

Advantages of EBM:
- High precision and accuracy
- Non-contact process, no tool wear
- Can achieve deep holes with high aspect ratios
- Suitable for a wide range of materials
- Can achieve complex geometries

Disadvantages of EBM:
- Limited material removal rate
- High cost of electron beam equipment
- Safety concerns due to electron radiation
- Limited availability of electron beam machines

Applications of EBM:
- Aerospace and defense industries
- Medical devices manufacturing
- Microelectronics and semiconductor fabrication
- Research and development of advanced materials

4. Ultrasonic Machining (USM): USM is a non-conventional machining process that uses

high-frequency ultrasonic vibrations combined with abrasive slurry to remove material from a
workpiece. It is commonly used for drilling, milling, and surface finishing of brittle materials.

Advantages: High precision, ability to work on brittle materials, and no thermal damage.

Disadvantages: Limited material removal rate, potential for tool wear, and challenges in
controlling vibrations.

Applications: Electronics (micro-drilling of printed circuit boards), optics (fabrication of

micro-lens arrays), and aerospace (hole drilling in ceramic components).

5. Laser Jet Machining (LJM): LJM is a non-conventional machining process that uses a
high-energy laser beam combined with a high-velocity jet of water or abrasive slurry to
remove material from a workpiece. It is commonly used for cutting, drilling, and surface
modification of materials.

Advantages: High precision, non-contact process, and ability to work on a wide range of
materials.

Disadvantages: Potential for thermal damage, limited material thickness, and high costs of
equipment.

Applications: Aerospace (hole drilling in turbine blades), electronics (cutting and drilling of
printed circuit boards), and medical devices (fabrication of stents).
6. Electrical Discharge Machining (EDM): EDM is a non-conventional machining process
that uses electrical discharges between a tool and a workpiece to remove material. It is
commonly used for cutting, drilling, and shaping of electrically conductive materials.

Advantages: High precision, ability to work on brittle materials, and no thermal damage.

Disadvantages: Limited material removal rate, potential for tool wear, and challenges in
controlling vibrations.

Role of CAM, AI, IoT, 5G: -

- CAM software is used to program and control the movement of the laser beam for precise
machining.
- AI algorithms can optimize the laser parameters for improved machining efficiency and
quality.
- IoT can enable real-time monitoring of process parameters for quality control and predictive
maintenance.
- 5G can enable faster and more reliable communication between machines, allowing for
remote monitoring and control of the machining process.

Q-5. What's MEMS and their design /role in today’s industries specifically Auto,
Defense, Aerospace, Health, Power sectors, with examples.

Ans-
MEMS stands for Micro-Electro-Mechanical Systems. It is a technology that integrates
micro-scale mechanical components, sensors, actuators, and electronics into a single
system on a microchip. MEMS devices are widely used in various industries, including
automotive, defense, aerospace, health, and power sectors, due to their small size, low
power consumption, and high performance. Here are some examples of MEMS and their
roles in different industries:

1. Automotive Industry: MEMS sensors are commonly used in the automotive industry for
applications such as airbag deployment, tire pressure monitoring, vehicle stability control,
and engine management. For example, MEMS accelerometers and gyroscopes are used in
electronic stability control systems to detect vehicle motion and orientation, allowing the
system to apply appropriate corrective actions to improve vehicle safety and performance.

2. Defense Industry: MEMS devices have significant roles in the defense industry for
applications such as inertial navigation systems, smart munitions, and surveillance systems.
For instance, MEMS-based inertial sensors, such as accelerometers and gyroscopes, are
used in guidance and navigation systems of missiles, drones, and other defense platforms to
provide accurate and reliable motion sensing capabilities.

3. Aerospace Industry: MEMS devices are used in the aerospace industry for various
applications such as vibration monitoring, structural health monitoring, and flow control. For
example, MEMS-based pressure sensors are used in aircraft for measuring airspeed,
altitude, and cabin pressure, providing critical data for flight control and safety.
4. Health Industry: MEMS devices are utilized in the health industry for applications such as
wearable devices, drug delivery systems, and implantable sensors. For instance,
MEMS-based biosensors can be used in wearable health monitoring devices to measure
parameters such as heart rate, blood pressure, and glucose levels, enabling personalized
and continuous health monitoring.

5. Power Industry: MEMS devices find applications in the power industry for energy
harvesting, energy storage, and smart grid systems. For example, MEMS-based vibration
energy harvesters can convert mechanical vibrations from machinery or infrastructure into
electrical energy, which can be used to power wireless sensor nodes for condition monitoring
or other low-power applications.

In summary, MEMS devices play critical roles in various industries, enabling innovative
solutions and improving performance in areas such as automotive safety, defense systems,
aerospace navigation, health monitoring, and energy management. Their small size, low
power consumption, and high performance make them highly suitable for integration into a
wide range of applications in today's industries.