Chemical Milling

                                                                                       
• chemical milling/blanking is a
chemical process that dissolves material
from unmasked (unprotected) areas of
metallic parts immersed in a tank of
heated and agitated chemical reagents. 
The term "blanking" denotes small, thin
workpieces, and "milling" indicates
relatively large workpieces.
  

(a) Schematic illustration of the

chemical machining process. Note
that no forces or machine tools are
involved in this process.

(b) Stages in producing a profiled

cavity by chemical machining; note
the undercut.
• considerable
advantages compared
to punching, laser-
cutting and wire-
erosion

(top) Weight reduction of space launch vehicles by

chemical milling
aluminum-alloy plates. These panels are chemically
milled after the plates have first been formed
into shape by processes such as roll forming or
stretch forming.

(left) Missile skin-panel section contoured by

chemical milling to improve the stiffness to-weight
ratio of the part.
• Chemical milling is used to reduce
the overall weight and other non
desirable factors of a workpiece
Process of Chem. Milling
1. Artwork and Negative Preparation

An image is printed by a program with a laser plotter directly to the film at any size
needed
2. Photoresist Application / Exposure / Develop

Apply Photoresist coating to make the metal sensitive to light.

Expose coated metal to UV light source which applies the image from the art work to the metal part.
Treat exposed metal part with a developing solution which removes the soft portion of the Photoresist.

3. Etching / Resist Removal

Process the metal through chemical etcher which dissolves all metal not protected by the hardened photoresist
coating.
 
Electrochemical Machining (ECM)

• uses an electrolyte at a high rate

from the tool piece to wash away
the metal ions from the
workpiece
• the tool is usually solid or tubular
form
• Material removal rate is 1.5 –
4mm³
• ECM was developed in 1929
• Not as widely used as other processes
• Generally used to make complex cavities and
shapes
• Finishes parts burr-free and bright surfaces
• Never has any thermal damage to part or wear on
the tools
Parts From Electrochemical Mill
Replacement Knees
Design Considerations for ECM
• ECM is not suitable for producing sharp edges or flat sufaces
• Flow of electrolyte can become difficult
• Designs should make provision for a small taper for holes to be
machined
Electrochemical Grinding (ECG)
• Process that combines electrochemical machining
with conventional grinding
• Grinder wheel is embeded with abrasive particles
of dimond or aluminum oxide
 • Abrassives on the spindle have two functions
• To act as insulators between the wheel and workpiece
• To remove electrolytic products from the work area

• Majority of material is removed by the

electrolytic action, less than 5% is removed by
the wheel
• The ECG process is similar to that of milling, and
grinding
• Much better than traditional grinding where wheel
wear is high