ET 223

Nontraditional
Machining
I. Chemical Machining

n is a refinement of the process once

used by photoengravers to prepare
printing cuts and plates.
n Chemicals are employed to etch away
selected portions of the metal to
produce an accurately contoured part.
n Two Categories:
n Chemical Milling

n Chemical Blanking
A. Chemical Milling (Contour Etching)

n Part is immersed in an etchant (strong

alkaline solution) where the resulting
chemical action removes the desired
metal.
n Areas that are not subject to metal
removal are protected by masks
(special coating material) that do not
react to the etchant.
n Employed to reduce the weight of sheet
metal parts for aerospace industries.
Sample of chemical milling
B. Chemical Blanking (Photoetching)

n Involves total removal of metal from

certain areas by chemical reaction
n Used by aerospace and electronics
industries to produce ultra thin, and
small parts.
n Can be worked on metal foil as thin as
0.00008”.
n Cigarette paper is about 0.001”
n Not recommended for metal thicker
than 0.09”
II. Electromachining Processes

n Electrical energy is applied directly to

remove metal by erosion. No mechanical
force.
n It is a chipless process. The particles are
disposed of completely by vaporization or
are reduced to microscopic particles.
n Two kinds:
n Electrical discharge machining (EDM)
• Wire and RAM (Vertical or Plunge)
n Electrochemical Machining (ECM)
A. EDM
n Electric current is stored in a capacitor then
discharged from the tool (cathode: Negative) to
the work (anode: Positive).
n Process is done thousands of times per sec.
n 80-90% of EDM work produces production
casting, forging, stamping, and extrusion molds.
n Parts of EDM machines
n Power Supply
n Electrode; cutting tool
n Servomechanism; control electrode movements
n Dielectric fluid; to form nonconductive barrier between
the electrode and the work at the arc gap.
Diagram of EDM process
EDM process
Sample EDM electrodes
B. Wire Cut EDM

n A process similar to band saw cutting.

n It makes use of a small diameter wire
electrode in place of saw blade.
n It differs from EDM in that a fine, moving
wire electrode is used for cutting instead
of a solid electrode.
n The technique is ideal for CNC operations.
Wire Cut EDM
III. Electron Beam Machining (EBM)

n Used mainly for welding

n The most precise and versatile of the
new machining techniques
n Possible to drill a hole as small as
0.0002” and mill slots of 0.0005” wide.
IV. Laser Beam Machining (LBM)

n Laser = Light Amplification by

Stimulated Emission of Radiation
n Laser melts and vaporizes the material.
n Can create temp up to 75,000F
n Seven times the average temperature of
the sun
n Used to cut, weld, heat-treat and trim
with great accuracy
n Usually controlled by NC
Waterjet Cutting
n High pressure water jet
n 30,000 – 60,000 psi
n Cuts through anything
n 2-dimensional cuts
n Newer machines cut in 5-axes
n Used in all industries
This Wed. & Next Mon.
n Wed.: Review for Mid-term
n Bring questions and concerns
n Mon.: Mid-Term