Chemical Energy Methods

These methods are suitable for high volume manufacturing activities. These have very low tooling costs and used for low end to high end product manufacture. Since, material removal takes ,place by chemical action, there are no thermal or mechanical stresses on the machined part. Also, machining action is from all round the tool, hence the production time is Jess for a given component.

Chemical Process
Chemical milling (CHM) is the controlled chemical dissolution (CD) of the workpiece material by contact with a strong reagent. Special coatings called maskants protect areas from which the metal is not to be removed. The process is used to produce pockets and contours and to remove materials from parts having a high strength-to-weight ratio.

CHM consists of the following steps:

Preparing and precleaning the workpiece surface. This provides good adhesion of the masking material and assures the absence of contaminants that might interfere with the machining process. Masking using readily strippable mask, which is chemically impregnable and adherent enough to stand chemical abrasion during etching. Scribing of the mask, which is guided by templates to expose the areas that receive CHM. The type of mask selected depends on the size of the workpiece, the number of parts to be made, and the desired resolution of details. Silk-screen masks are preferred for shallow cuts requiring close dimensional tolerances. The workpiece is then etched and rinsed, and the mask is removed before the part is finished.

During CHM the depth of the etch is controlled by the time of immersion. In order to avoid uneven machining, the chemicals that impinge on the surface being machined should be fresh.

Maskants:

CHM will not eliminate surface irregularities, dents, scratches, or waviness. Successive steps of mask removal and immersion as shown in Fig. can achieve stepped cuts.

Synthetic or rubber base materials are frequently used as maskants. They should possess the following properties: Tough enough to withstand handling Inert to the chemical reagent used Able to withstand heat generated by etching Adhere well to the work surface Scribe easily Able to be removed easily after etching Multiple coats of the maskant are frequently used to increase the etchant resistance and to avoid the formation of pinholes on the machined surfaces.

Etchants:

Etchants are highly concentrated acidic or alkaline solutions maintained within a controlled range of chemical composition and temperature. They are capable of reacting with the WP material to produce a metallic salt that dissolves in the solution.

Process parameters CHM process parameters include the reagent solution type, concentration, properties, mixing, operating temperature, and circulation. The process is also affected by the maskant and its application. These parameters will have direct impacts on the workpiece regarding the following: Etch factor (d/T ) Etching and machining rate Production tolerance Surface finish To machine high-quality and low-cost parts using CHM, we must consider the heat treatment state of the workpiece, the grain size and range of the workpiece material, the size and finish control prior to CHM, the direction of rolling and weld joints, and the degree of cold work.

advantages

Weight reduction is possible on complex contours that are difficult to machine conventionally. Several parts can be machined simultaneously. Simultaneous material removal from all surfaces, improves productivity and reduces wrapping. No burr formation. No induced stresses, thus minimizing distortion and enabling machining of delicate parts. Low capital cost of equipment, and minor tooling cost. Quick implementation of design changes. Less skilled operator is needed. Low scrap rate.

Disadvantage

Only shallow cuts are practical. Deep narrow cuts are difficult to produce. Handling and disposal of etchants can be troublesome. Masking, scribing, and stripping are repetitive, time-consuming, and tedious. Surface imperfections, if any, are reproduced. For best results, metallurgical homogeneous surfaces are required. Porous castings yield uneven etched surfaces. Welded zones are frequently etched at rates that differ from base metal.