MENG 439

Dr. L. K. Gaafar

Chemical Machining

Dr. Lotfi K. Gaafar 2002

Chemical Machining
 Was developed based on the observation that chemicals attack metals and etch them by using chemical dissolutions.  Is the oldest of nontraditional machining processes, and has been used to engrave metals and hard stones.

 Can be classified into: Chemical Milling Chemical Blanking

Dr. Lotfi K. Gaafar 2002

Chemical Milling
    Shallow cavities on sheets, plates, etc Selective attack by chemicals on workpiece Used in aerospace industry Used to fabricate microelectronic devices

Dr. Lotfi K. Gaafar 2002

Chemical Blanking
    Blanking of sheet metals Material removed by chemical dissolution Used to produce fine screens, flat springs, etc Very cheap but efficient

Dr. Lotfi K. Gaafar 2002

Characteristics of Chemical Machining

     Shallow removal of material(up to 12mm) Blanking of thin sheets Low tooling & equipment cost Suitable for low production runs Material removal rate(0.1mm/min)

Dr. Lotfi K. Gaafar 2002

Photo Chemical Machining (PCM)

 PCM is a material removal process using chemicals (etchants) to produce high precision parts.  This process is also known as Photo Etching, Chemical Blanking and Photo Chemical Milling.

Dr. Lotfi K. Gaafar 2002

PCM Process
1. Artwork- generate design using CAD systems, then plot it using a high precision laser plotter to produce photo-tool. Chemically clean the metal surface. Coat both sides of the plate with photoresist. (photoresist is a polymer that adheres to the metal when exposed to UV light).
http://web.mit.edu/ndemarco/www/chemmilling/slide6.html

2. 3.

Dr. Lotfi K. Gaafar 2002

PCM Process Cont.

4. Expose plate and phototool to ensure image transfer. Spray metal with etchant or dip it in hot acidic solution to etch all material other than part covered with photoresist (1-15 min.). Rinse the plate to ensure photoresist and etchant removal.

5.

6.

http://web.mit.edu/ndemarco/www/chemmilling/slide6.html

Dr. Lotfi K. Gaafar 2002

Advantages
 Low Tooling Cost- all tooling is produced by CAD systems at a low cost with a short creation time.  Low Modification Cost- short runs are possible at a low cost, thus, design can be easily modified.  Burr and Stress Free.  Complex Designs.  Thin Plates as thin as 0.005.

Dr. Lotfi K. Gaafar 2002

Materials
       Aluminum Chromium Copper (oxygen free, rolled) Nickel Steel (carbon, stainless) Lead Zinc

Dr. Lotfi K. Gaafar 2002

Applications
High Precision Parts and Decorative Items
      Gaskets Washers Sensors Nameplates Jewelry Microprocessor Chips

http:// www.suron.com

Dr. Lotfi K. Gaafar 2002