A Review of Assisted / Augmented Manufacturing Processes

Abstract Manufacturing has a history almost as long as the humankind, but as materials get more and more complex due to material science technology, manufacturing them becomes increasingly difficult. Using processes in combination has been a common practice. Similarly, using a simple process to aid a more complex process has often been employed. However, more advanced technologies have been developed to manufacture difficult-to-manufacture materials, as well as advanced auxiliary techniques to aid the main manufacturing process. In most of these processes, the aim is to improve the manufacturability of the part. Initial considerations to improve manufacturability were focused on being able to produce the part in ways aligning with the design. For example, in hot forging, it was not possible to achieve the right product without the aid of the secondary process (heating). As the manufacturing field evolved, needs of the industry changed to improving part quality and lowering manufacturing costs. Modern methods of assisting main manufacturing processes focus on ensuring (1) an extended use of the tool quantified by lower tool wear and higher tool life, (2) improved machine capabilities quantified by lower maintenance times and higher automation, (3) improved final product quality quantified by dimensional accuracy and surface, subsurface, and bulk material quality, and (4) increased sustainability of the process quantified by lower resource use such as machine power and lubrication. In this study, an overview of the use of assistance in manufacturing processes is provided. The review is focused on more modern techniques such as laser, electrical, magnetic field, and ultrasonic assistance, more modern materials that are difficult-to-manufacture such as hardened steels and titanium and nickel-based alloys, and on machining processes that are more imminent for the critical industries such as automotive, aerospace, energy production, and biomedical industries.