From the last class presentations following topics were covered.

1. Importance of ultrasonic welding.

2. Applications and analysis of 3D Gel printing.
3. Implementation of hydro gel materials.
4. What is friction drilling?
5. How to improve formability of steel by using hydro forming?
6. Significance of Single point incremental forming.
7. Advancement in 3D printing.

What is ultrasonic welding?

In US welding, frictional heat produced by ultrasonic waves and force

used for joining process.
Ultrasonic waves are transferred to the material under pressure in
sonometer
Waves range from 15 ~ 16 Hz.
It may or may not depend up on external heat.

Advantages:
No heating and melting occurs

Transducer, sonotrode and anvil are the main components of US welding.

The parts to be consolidated are held under pressure and subjected to ultrasonic
vibrations, for the most part at a frequency of 20 or 40kHz.

After a preset time, the ultrasonic vibration is turned off, welding

pressure is kept up and the liquid thermoplastic sets to frame a weld. With weld
times regularly short of what one moment, the procedure is quick. Weld quality
methodologies that of the parent material, and with right part and joint design,
hermetic seals are conceivable.
Different advantages of ultrasonic welding incorporate great vitality proficiency,
high efficiency no sweat of robotization. The fundamental impediment is that
the most extreme length of joint is around 250mm.

This is because of a few components: control restriction of

ultrasonic transducers; failure of ultrasonic horns to transmit high powers; and
adequacy control challenges because of the way that joints of this length are
equivalent to the wavelength of the ultrasound in the horn.

Analysis of 3D gel printing.

Combination of gelation and 3D printing and developing new method.

3D printing and gelation/thermogelation allow for new opportunities in
biomedical researchincluding the capacity to generate custom cell
scaffolds, and potentially fabricate tissues, by placing cells where they are
desired in a medium that supports their growth

Implementation of hydro gel materials:

Hydro gel products constitute a group of polymeric materials, the hydrophilic

structure of which renders them capable of holding large amounts of water in
their three-dimensional networks.

Extensive employment of these products in a number of industrial and

environmental areas of application is considered to be of prime importance. As
expected, natural hydro gels were gradually replaced by synthetic types due to
their higher water absorption capacity, long service life, and wide varieties of
raw chemical resources. Literature on this subject was found to be expanding,
especially in the scientific areas of research.

MEMS
 MEMS, is a technology that in its most
general form can be defined as
miniaturized mechanical and electro-
mechanical elements that are made using
the techniques of micro fabrication.

The one main criterion of MEMS is that

there are at least some elements having
some sort of mechanical functionality
The process involved in Mems is like Pre processing, layering, post-processing
and micro fluidics.

Single point incremental forming:

Single point incremental forming is a rather new sheet metal forming process
forming by local stretching of the sheet with a pin tool following a tool path
controlled by a CNC machine.

The basic components of the process are

1) The sheet metal blank.

2) The blank holder.
3) The backing plate.
4) The rotating single point forming tool.

Friction drilling:
Friction drilling is a process in which uses a bit that doesnt have cutting
edge and it may also known as form drilling or thermal drilling.
 Conical bit may spun at high speeds and with high pressure that may
occur friction to the bore through the material

These are the five stages involved in friction drilling.

Considerations:
Can be observed sheared microstructure near the bore hole.
Must maintain the planned temperature for entire process.
Heat dissipations.
Must control the heat by that work piece will not melt.

The drill consists of five regions they are conical, central, cylindrical, shoulder
and shank regions. The first three regions will determine thrust and torque of
friction drilling.

By using IR camera, temperature of work piece will be monitored. It is sensitive

to thermal radiation wavelength from 3 to 5m. The IR image capturing was set
at 60 frames / s with 0.1 ms integration time.

Experimental example:
Experiment involves the thermal friction drilling that effects on surface
temperature, thrust force and torque of the work piece material.
When I am working in Thermal power plant, we use to make a sample test of all
types of lubrication oils to determine the NASH value and by that we can
increase the life of machine. So for every oil tanks we need to erect a small
sample pipe line to the oil supply line of the main oil tank.
Firstly we erected or joined the pipe line by doing regular drilling and
welding process. But we faced lot of problems as drilled particles or debris got
mixed in oil and by that rotary parts get damaged. For the alternate we got an
idea to go forward with Friction drilling to overcome the problem occurred
before.

And also this method can be used in manufacturing of vehicles.

Some aspects and conclusions during the experiment:

Thrust force and torque increases gradually with increasing friction angle.
Thrust force and torque decreases with increasing spindle speed.
Work piece surface temperature increases when spindle speed increases.
Increasing or decreasing the friction angle and FCAR has no significant
effect on work piece surface temperature.
Feed rate increases when surface roughness increase.
Feed rate increases when bushing length decreases.

Questions:
How can we classify both short and long friction drilling?

What is the minimum and maximum material thickness?

During ultrasonic welding process, what are the effects on glass

reinforcement in a plastic?