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    Chemical Machining and Milling

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    ahmed
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    Chemical Machining and Milling

    Uploaded by

    ahmed
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    By ahmed

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    By ahmed

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    76 views2 pages

    Chemical Machining and Milling

    Uploaded by

    ahmed
    By ahmed

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    CHEMICAL MACHINING AND MILLING

    Introduction

    Chemical machining (CM) is the controlled dissolution of workpiece material (etching) by


    means of a strong chemical reagent (etchant). In CM material is removed from selected areas
    of workpiece by immersing it in a chemical reagents or etchants; such as acids and alkaline
    solutions. Material is removed by microscopic electrochemical cell action, as occurs in
    corrosion or chemical dissolution of a metal. This controlled chemical dissolution will
    simultaneously etch all exposed surfaces even though the penetration rates of the material
    removal may be only 0.00250.1 mm/min. The basic process takes many forms: chemical
    milling of pockets, contours, overall metal removal, chemical blanking for etching through
    thin sheets; photochemical machining (pcm) for etching by using of photosensitive resists in
    microelectronics; chemical or electrochemical polishing where weak chemical reagents are
    used (sometimes with remote electric assist) for polishing or deburring and chemical jet
    machining where a single chemically active jet is used. A schematic of chemical machining
    process is shown in Figure 6.

    Figure 6: (a) Schematic of chemical machining process (b) Stages in producing a profiled
    cavity by chemical machining (Kalpakjain & Schmid)

    Chemical milling

    In chemical milling, shallow cavities are produced on plates, sheets, forgings and extrusions.
    The two key materials used in chemical milling process are etchant and maskant. Etchants are
    acid or alkaline solutions maintained within controlled ranges of chemical composition and
    temperature. Maskants are specially designed elastomeric products that are hand strippable
    and chemically resistant to the harsh etchants.

    Steps in chemical milling

    Residual stress relieving: If the part to be machined has residual stresses from the
    previous processing, these stresses first should be relieved in order to prevent warping
    after chemical milling.
    Preparing: The surfaces are degreased and cleaned thoroughly to ensure both good
    adhesion of the masking material and the uniform material removal.
    Masking: Masking material is applied (coating or protecting areas not to be etched).
    Etching: The exposed surfaces are machined chemically with etchants.
    Demasking: After machining, the parts should be washed thoroughly to prevent
    further reactions with or exposure to any etchant residues. Then the rest of the
    masking material is removed and the part is cleaned and inspected.

    Applications:

    Chemical milling is used in the aerospace industry to remove shallow layers of material from
    large aircraft components missile skin panels (Figure 7), extruded parts for airframes.

    Figure 7: Missile skin-panel section contoured by chemical milling to improve the


    stiffness- to- weight ratio of the part (Kalpakjain & Schmid)

    Source : http://nprcet.org/e%20content/Misc/e-Learning/
    Mechanical/III%20year/ME1303-GAS%20DYNAMICS%20AND%20JET%
    20PROPULSION.pdf

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