Introduction to Non-Traditional Machining (BME755D) Module 3 Notes

 The cost of machines is too much high to carry out this process.

 Skilled labour is needed to implement this metal removing process.

 It is only applicable to the hard materials mostly.

CHEMICAL MACHINING (CHM)

3.11 Introduction to CHM

Chemical machining is well known as nontraditional machining process and is controlled bychemical
dissolution of the machines work piece material by contact with a strong chemical [Link] is also
known as a chemical etching and almost all the material from metal to ceramics can be chemically
machined. Chemical machining process is employed where metal removal is difficult. Chemical
machining is a controlled dissolution of the work material by means of contact with a strong acidic
or alkaline chemical reagent. The major characteristics of chemical machining are material removal
rate, accuracy and surface finish.

3.12 Elements of process in CHM

The working principle of chemical machining is based on chemical etching. The part of the work
piece metal where material is to be removed is brought into contact with a strong corrosive chemical
called etchant. The etchant react with the workpiece in the material to be cut and causes the solid
material to be removed. Thus the metal is removed by the chemical attack of the etchant. The portion
of the work material where material is not to be removed is protected from chemical attack by means
special coating called as maskants. So by this chemical machining process from all metal to ceramic
substance can be machined with chemical machining process. This process of chemical reaction
between the material of the work piece and some chemical reagent use to produce a reaction between
then so that it can be removed easily .thus the surface of the workpiece is etched away, exposing the
lower layers, and the process is continued until the desired amount of material is removed.

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Procedure for Chemical Machining

1. Workpiece pre cleaning process: The surface of workpiece metal is cleaned thoroughly,
degreased and pickled by acid or alkalis. Pre cleaning is the most important method to remove oil,
grease, dirt, rust, or any foreign substance from the work surface to produce a good adhesion of
masking material.

2. Masking and scribing mask: Masking involves covering the portion of the workpiece metal
where material is not to be removed by the chemical action .masking with adhesive types or paints is
a common practice although rubber (elastomers) and plastics are also used. Since it is difficult to
apply maskant on small surface, the maskant is initially applied on a large surface

3. Etching: The unmasked surface of the workpiece is machined chemically with selected etchant.
Etching is carried out by immersing the work material in a tank of agitated etchant. The process is
carried out at high temperature depending on the etched material. Temperature control and agitation
during chemical machining. Erosion of the work material takes place from the exposed surface. The
work piece is converted into metallic salt, which is then dissolved and carried away in the etchant
solution.

4. Demasking: When etching is completed the mask is removed either through mechanical or
chemical means. Any etchant on the work material is also removed by cold water to clean. A
deoxidizing bath may also be required in order to remove the oxide coating or films left on the surface
of the work material.

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3.13 Maskants (Resists)

Masking material is known as Maskant which is used to protect workpiece surface from chemical
etchant. In another words maskants protect the portion of workpiece metal where material is not to
be removed by chemical action of the etchant. Polymer or rubber based materials are generally used
as a maskant material. Various maskant application methods can be used such as dip, brush, spray,
roller, and electro coating as well as adhesive tapes.

The type of maskant to be selected for machining is based on the following factors:

 Be inert to the chemical reagent used

 Chemical resistance required
 Be tough enough to withstand handling
 Adhere well to the work piece
 Allow itself to be scribed easily
 Be removed easily after etching
 Be inexpensive after etching
 Be able to withstand the heat generation by etching
 Availability and low cost

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3.14 Etchants
Etchants are acid or alkaline solutions maintained within a controlled range of chemical composition
and temperature. The workpiece material to be removed is sprayed or immersed in a suitable etchant.
Various etchant are available for machining different material as listed in table below.

The type of etchant to be selected for machining is based on following factor:

 Type of workpiece metal that is being etched

 Rate of metal removal
 Surface finish required
 Type of maskant used
 Depth of etch required
 Ability to regenerate the etchant solutions
 Un harmful Or non toxic to human operator
 Availability at low cost

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3.15 Types of CHM process

There are two type of chemical machining:
1. Chemical blanking method

Chemical blanking is a process of producing a part from thin sheet metal by chemically etching the
periphery of the desired shape. The material is removed by chemical dissolution. Chemical blanking
is used for parts that are otherwise typically produced by mechanical blanking presses from thin plates
and foil material. With mechanical presses, vibrations, backlash, and part distortion will make smaller
parts difficult to produce.

Chemical blanking process

Steps of chemical blanking: Chemical blanking process has several steps for producing machine
parts. These are given below:

1. Workpiece pre cleaning process: The surface of the workpiece metal is cleaned thoroughly,
degreased and pickled by acid and alkalis. Pre cleaning is of utmost importance in order to remove
oil, grease, dirt, rust or any foreign substance for the work surface so as to produce a good adhesion
of the masking material. The material is allowed to dry.

2. Masking: Masking involves covering the portions of the workpiece metal where material is not to
be removed by the chemical action of the etchant. A suitable maskant, say a polymer, rubber, or any
other material is selected based on the workpiece material. The maskant is applied on the work surface

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by various methods like dip, brush, spray, roller, electro-coating, and as well as adhesive tapes.

3. Etching: Removal of material from the workpiece take place by etching process. The workpiece
metal is either sprayed continuously with a selected etchant like ferric chloride on those portions
where the material is to removed, or immersed in a tank of agitated etchant, where the etchant
chemically attack those portions not masked. Erosion of the work material take place both inward and
laterally from the exposed(unmasked) surface. The work material is converted in to metallic salt,which
is the dissolved and carried away in the etchant solution.

4. Demasking: When etching is completed, the mask is removed either through mechanical orchemical

means Any etchant on the material is also removed with a wash or clear, cold water. A deoxidizing
bath may also be required in order to remove the oxide films left on the surface of the work material.

2. Chemical milling or contour machining method

Chemical milling is a process used to produce shapes by chemical etching selective portion of
material from the relatively large surface area of work metal. The main purpose is to produce shallow
cavity with complex profiles on plates, sheets forging, generally for the overall reduction of weight.
Chemical milling as shown in Figure below

Chemical milling process

Steps of Chemical Milling: Chemical machining process has several steps for producing machine
parts. These are given below

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1. Workpiece pre cleaning process: The workpiece material has to be cleaned in the beginning of
chemical machining process. The cleaning operation is carried out to remove the oil, grease, dust, rust
or any substance from the surface of material. A good cleaning process produces a good adhesionof
the masking material. There are two cleaning methods; mechanical and chemical methods. The most
widely used cleaning process is chemical method due to less damages occurred comparing to
mechanical one. Ultrasonic cleaning machine is applied with using special cleaning solution and
heating is beneficial during the cleaning process.

2. Masking and Scribing mask: Masking involves covering the portions of the workpiece metal where

material is not to be removed by the chemical action of the etchant. The selected masking material
should be readily strippable mask, which is chemically impregnable and adherent enough to stand
chemical abrasion during etching. Scribing mask is guided by templates to expose the areas that
receive chemical machining process. The selection of mask depends on the size of the workpiece
material, the number of parts to be produced, and the desired detail geometry. Silkscreen masks are
preferred for shallow cuts requiring close dimensional tolerances.

3. Etching: This step is the most important stage to produce the required component from the sheet
material. This stage is carried out by immerse type etching machine. The workpiece material is
immersed into selected etchant and the uncovered areas were machined. This process is generally
carried out in elevated temperatures which are depended on the etched material. Then the etched
workpiece is rinsed to clean etchant from machined surface.

4. Cleaning masking material: Final step is to remove masking material from etched part. The
inspections of the dimensions and surface quality are completed before packaging the finished part.

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3.16 Applications of CHM

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

 This process is best suited for production of printed circuits , where the basic connections of
the circuit consist of thin metal strips attached to a insulating board faced with a thin layer of
copper .
 Besides, it removes metal from a portion of entire surface of formed or irregularly shaped parts
such as forging casting, extrusions or formed wrought stock. The surface finish obtained in this
process is in the range of 0.5 to 2 µm.
 One of the major applications of chemical milling and blanking is in the manufacture.

3.17 Advantages of CHM

 Low tooling cost.

 Multiple machining can be done on a workpiece simultaneously.

 No application of force so on risk of damage to delicate or low strength workpiece.

 Complicated shapes/patterns can be machined.

 Machining of hard and brittle material is possible.

 Easy weight reduction

 No stress introduction to the workpiece

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3.18 Limitations of CHM

 Slower process, very low MRR so high cost of operation.

 Small thickness of metal can be removed.

 Sharp corners cannot be prepared.

 Difficult to chemically machine thick material (limit is depended on workpiece material, but
the thickness should be around maximum 10 mm)

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QUESTION BANK
ELECTROCHEMICAL MACHINING (ECM)
1. Mention advantages and disadvantages of Electrochemical machining (ECM).
2. Mention the applications of Electrochemical machining (ECM).
3. With a neat sketch explain Electrochemical grinding process (ECG).
4. With a neat sketch explain Electrochemical honing process (ECH).
5. Mention the advantages, disadvantages and applications of Electrochemical grinding process (ECG).
6. Mention the advantages, disadvantages and applications of Electrochemical honing process (ECH).
7. Describe various process parameters affecting ECM. (10 Marks) (VTU June/July 2011)
8. Differentiate between “fludging” and “non-fludging” electrolyte. (3 Marks) (VTU June/July 2011)
9. Explain with a neat diagram, electrochemical machining process. (6 Marks) (VTU Dec 2011)
10. With a neat schematic diagram, explain the electrochemical honing process. (8 Marks) (VTU Dec
2011)
11. Explain the advantages and limitations of ECM. (6 Marks) (VTU Dec 2011)
12. With a neat sketch, explain the working principle of ECM process. (8 Marks) (VTU June 2012)
13. Sketch and explain different types of tools used in ECM process. (6 Marks) (VTU June 2012)
14. List the advantages, limitations and applications of ECM process. (6 Marks) (VTU June 2012)
15. Explain ECM with the schematic diagram. (5 Marks) (VTU Dec 2012)
16. Explain functions of electrolytes used in ECM and name 3 electrolytes with their specialities. (5
Marks) (VTU Dec 2012)
17. Explain chemistry of ECM with the circuit. (5 Marks) (VTU Dec 2012)
18. Theoretically estimate metal removal rate and electrode feed rate of ECM. (5 Marks) (VTU Dec
2012)
19. With suitable sketches. Explain the metal removal mechanism in electro chemical grinding. (8
Marks) (VTU June/July 2013)
20. Why are chemical machining and electro chemical machining considered as chipless machining?
Explain the mechanisms of metal removal on both cases and compare it with conventional grinding
process. (12 Marks) (VTU June/July 2013)
21. Explain different elements of electrochemical machining process. (6 Marks) (VTU June/July 2014)
22. Explain with sketch the electrochemical grinding operation. (6 Marks) (VTU June/July 2014)
23. What are the advantages and disadvantages of ECM? (6 Marks) (VTU Dec 2014/Jan 2015)

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 Introduction to Non-Traditional Machining (BME755D) Module 3 Notes

24. What are the factors that influences oxidation of ECM? (4 Marks) (VTU Dec 2014/Jan 2015)
25. Explain the principle of electro chemical grinding, with a neat sketch. (10 Marks) (VTU Dec
2014/Jan 2015)
26. Explain the chemistry of ECM process with diagram. (8 Marks) (VTU June/July 2015)
27. List the functions of electrolyte in ECM process. (8 Marks) (VTU June/July 2015)
28. Explain with diagram, working of electro chemical grinding (ECG). (8 Marks) (VTU June/July
2015)
29. Draw schematic sketch of electro chemical machining and explain briefly the elements of ECM
process. (10 Marks) (VTU June/July 2016)
30. Explain with neat schematic diagram of electro chemical grinding and their advantages and
application. (10 Marks) (VTU June/July 2016)
CHEMICAL MACHINING (CHM)
1. Mention advantages and disadvantages of Chemical machining (CHM).
2. Mention the applications of Chemical machining (CHM).
3. Discuss the factors to be considered for selection of ‘Maskants’ and the types that are used in
‘chemical machining’. (10 Marks) (VTU June/July 2011)
4. Differentiate between ‘chemical milling’ and chemical blanking’. (4 Marks) (VTU June/July 2011)
5. Write a note on ‘etchants’ in ‘chemical milling’. (6 Marks) (VTU June/July 2011)
6. What is chemical machining? Explain briefly the elements of the process. (7 Marks) (VTU Dec
2011)
7. Explain briefly, the chemical milling process with the help of neat flow chart. (7 Marks) (VTU Dec
2011)
8. Discuss the advantages and applications of CHM. (6 Marks) (VTU Dec 2011)
9. What are Maskants used in chemical machining? Explain the different types of it. (10 Marks) (VTU
June 2012)
10. What are the factors to be considered in the selection of etchant? (4 Marks) (VTU June 2012)
11. Explain the chemical blanking process stepwise with the flow chart. (10 Marks) (VTU Dec 2012)
12. Write a note on etchants indicating factors to select. (6 Marks) (VTU Dec 2012)
13. Write advantages of chemical machining. (4 Marks) (VTU Dec 2012)
14. Explain in brief the following in chemical machining process: i) Maskants. ii) Etchants. (8 Marks)
(VTU June/July 2013)
15. With the help of neat sketches. Explain the different steps involved in chemical blanking. (12 Marks)

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 Introduction to Non-Traditional Machining (BME755D) Module 3 Notes

(VTU June/July 2013)

16. Explain with flow chart the chemical blanking process. Mention its applications. (10 Marks) (VTU
June/July 2014)
17. Explain with flow chart the chemical milling process. Mention its advantages and applications. (10
Marks) (VTU June/July 2014)
18. Explain the principle steps involved in chemical milling to produce pockets and contours. (6 Marks)
(VTU Dec 2014 / Jan 2015)
19. List out the advantages and disadvantages of chemical machining. (8 Marks) (VTU Dec 2014 / Jan
2015)
20. List out the major applications of CHM. Further process application related to improving the
characteristics. (6 Marks) (VTU Dec 2014 / Jan 2015)
21. Explain the elements of chemical machining process. (6 Marks) (VTU June/July 2015)
22. Explain with flow chart the chemical blanking process. (10 Marks) (VTU June/July 2015)
23. Mention the limitations of chemical machining process. (4 Marks) (VTU June/July 2015)
24. What are the factors on which the selection of a resist for all in chemical machining depend? (3
Marks) (VTU June/July 2016)
25. Explain the elements of process (i) Maskants or resist. (ii) Etchants in CHM. (8 Marks) (VTU
June/July 2016)
26. Explain with sketch progressive stages of metal removal in chemical blanking. (6 Marks) (VTU
June/July 2016)
27. List the applications of chemical machining. (3 Marks) (VTU June/July 2015)

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