Machining Process 2

Report
chemical Machining
(IBM)

PRESENTED BY:
‫حسن محمود حسن الدسوقي‬
Report supervisor:
‫عبدالخالق العدل‬.‫د‬

PRESENTED ON: 12-12-2023.

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Chemical machining (CHM):
Chemical machining (CHM), also known as chemical milling or
chemical etching, is a subtractive manufacturing process used to
selectively remove material from a workpiece using chemical
reactions. It is commonly used to shape and contour intricate parts
with high precision.

Theory of Chemical Machining:

The theory behind chemical machining involves understanding the chemical
reactions between the workpiece material and the etchant solution. The
etchant, which is a chemical solution or bath, is carefully chosen based on its
ability to dissolve the material being machined while preserving the masking
material or areas that should remain untouched.

Process of Chemical Machining:

Material Selection: The material of the workpiece should be compatible
with the etchant solution. Metals such as aluminum, steel, titanium, and
copper are commonly used due to their chemical reactivity with specific
etchants.
Masking: The workpiece is coated with a masking material, such as
photoresist or polymer films, to protect the areas that should not be etched.
The masking material acts as a barrier, preventing the etchant from reaching
those regions.

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Etchant Selection: The etchant is chosen based on its chemical
compatibility with the workpiece material. The etchant should selectively
react with the material to be removed while not affecting the masking
material or other desired areas.

Etching Process: The masked workpiece is immersed in the etchant

solution, and the chemical reactions start to occur. The etchant attacks the
exposed areas of the workpiece, dissolving the material and creating the
desired shape or pattern.

Etching Rate Control: The etching rate, or the speed at which material is
removed, can be controlled by various factors, including temperature,
concentration of the etchant, agitation, and exposure time. These
parameters are carefully adjusted to achieve the desired level of material
removal and maintain dimensional accuracy.

Rinse and Finish: After the desired material removal is achieved, the
workpiece is thoroughly rinsed to remove any remaining etchant. The
masking material is then removed, and the workpiece may undergo
additional finishing processes, such as cleaning, deburring, or surface
treatment.

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Components of Chemical Machining:

Tank:
This process has a tank with its face open. The tank is built of strong metal
coated with materials that are non-reactive to etchant depending on the
applications and concentration of chemical reagent.

Heating coil:
A heating coil is mounted at the lowest section of the tank to maintain the
temperature of the tank at a constant level. It is practical that in any metal
removal process the heat generation is natural. Also, the coil does cool in
necessary conditions.

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Stirrer:
A stirrer is placed in the etchant whose main purpose is to mix the etchant
consistently to maintain a uniform concentration and heat along the
volume of the etchant. It is well known to us that the hot particles always
accumulate at the top, leaving the cold below.

So, to spread the heat uniformly along the etchant, a stirrer is used. The
stirrer also helps in the flushing of dissolved metal from the workpiece
simultaneously breaking the bubbles formed during machining due to
oxidation.

Workpiece:
The workpiece is held in the etchant by the use of a hanger in the case of small
applications. The length of the hanger is fastened over a masked area so that the fixing
of the workpiece does not disturb the machining zone.

In the case of a larger workpiece, fixtures coated with rubbers and polymers are used to
hold the workpiece.

Applications of Chemical Machining:

Aerospace Industry: Chemical machining is extensively used in the
aerospace industry for manufacturing components such as turbine blades,
engine parts, airfoils, and complex geometries. It allows for the production
of lightweight parts with intricate designs and precise tolerances.

Electronics Industry: Chemical machine is employed in the electronics

industry for manufacturing printed circuit boards (PCBs). It enables the
selective removal of copper or other conductive materials to create circuit
traces, pads, and vias, thus forming the electrical pathways on the PCB.

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Automotive Industry: Chemical machining finds applications in the
automotive industry for producing various components like gears,
transmission parts, fuel injection nozzles, and engine components. It allows
for the production of lightweight parts with complex shapes and high
precision.

Medical Device Industry: Chemical machining is utilized in the medical

device industry for manufacturing components like surgical instruments,
orthopedic implants, and microfluidic devices. It enables the production of
intricate designs and precise features required for medical applications.

Microelectronics Industry: Chemical machining plays a crucial role in the

microelectronics industry for fabricating microelectromechanical systems
(MEMS), microstructures, and microfluidic devices. It allows for the creation
of intricate patterns and features on a small scale.

Defense and Military Applications: Chemical machining is employed in

defense and military applications for manufacturing components such as
missile parts, radar components, and armor plates. It enables the production
of complex shapes and lightweight structures.

Tool and Die Making: Chemical machining is used in tool and die making
processes to produce molds, dies, and other tooling components with
intricate details and precise geometries.

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Advantages of Chemical Machining:
Complex Geometries: Chemical machining enables the production of
intricate and complex shapes that may be difficult or impossible to
achieve with traditional machining methods. It allows for the creation of
fine details, thin walls, and intricate patterns without the need for
complex tooling or multiple machining operations.

High Precision: Chemical machining can achieve high levels of

dimensional accuracy and tight tolerances. The process is capable of
producing parts with precise features and intricate designs, ensuring
consistency and uniformity across multiple workpieces.

Cost-Effective: Chemical machining can be a cost-effective

manufacturing process, especially for complex parts. It eliminates the
need for expensive tooling and reduces the number of machining
operations required. The process allows for the simultaneous production
of multiple parts on a single workpiece, resulting in cost savings.

Material Versatility: Chemical machining can be used with a wide

range of materials, including metals, alloys, and even some polymers. It
is not limited to specific material types and can accommodate various
workpiece materials with different chemical compositions and
properties.

Minimal Mechanical Stresses: Chemical machining is a non-

mechanical process, which means there is minimal mechanical stress or
distortion applied to the workpiece. This is particularly beneficial for
delicate or thin materials that may be susceptible to deformation or
damage during traditional machining processes.
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Surface Finish: Chemical machining can achieve excellent surface
finishes, often eliminating the need for additional finishing operations.
The process can produce smooth surfaces with high aesthetic appeal,
reducing the time and cost associated with post-processing.

Scalability: Chemical machining is scalable and can be adapted to

accommodate both small-scale prototyping and large-scale production.
The process can be easily adjusted to meet different production volumes
and requirements.

Design Flexibility: Chemical machining offers design flexibility,

allowing for the creation of customized parts with unique shapes and
features. It enables designers to explore creative and intricate designs
that may not beachievable with other manufacturing processes.

Reduced Material Waste: Chemical machining is a subtractive process

that selectively removes material only from the areas required,
minimizing material waste. This can result in cost savings and reduced
environmental impact.

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Disadvantages of Chemical Machining:
Limited Material Compatibility: Chemical machining is not suitable for
all materials. It is primarily used for metals, alloys, and some polymers,
but certain materials may not be chemically reactive with available
etchants. Additionally, some materials may require specialized etchants
or processes, which can increase the complexity and cost of the
operation.
Process Complexity: Chemical machining requires careful process
planning and control. Factors such as etchant selection, concentration,
temperature, and process parameters need to be precisely controlled to
achieve the desired material removal rate, dimensional accuracy, and
surface finish. The process complexity can make it more challenging to
implement and optimize compared to simpler machining methods.

Environmental Concerns: Chemical machining involves the use of

etchants that can be corrosive, toxic, or hazardous to health and the
environment. Proper safety measures and waste management processes
need to be in place to handle and dispose of the etchants safely. The
disposal of the waste etchant solution requires adherence to
environmental regulations, which can add to the overall complexity and
cost of the process.

Masking Complexity: Applying the masking material to protect the areas

that should not be etched can be a complex and time-consuming process.
Achieving uniform and precise masking coverage can be challenging,
particularly for intricate designs or complex geometries. Inadequate
masking can result in etchant penetration where it is not desired, leading
to dimensional inaccuracies or surface defects.

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Etching Rate Control: Achieving precise control over the etching rate can
be challenging in chemical machining. Factors such as temperature,
concentration, and agitation need to be carefully controlled to ensure
consistent material removal rates across the entire workpiece. Improper
control can lead to dimensional variations and surface finish
inconsistencies.

Surface Integrity: While chemical machining can produce excellent

surface finishes, there is a risk of surface contamination or residual
etchant remaining on the part. Thorough rinsing and cleaning processes
are required to remove any residual etchant and ensure the part's
surface integrity. Inadequate rinsing can result in surface defects or
corrosion over time.

Limited Thickness Control: Chemical machining is typically more suitable

for thin materials, and controlling the etching depth in thicker parts can
be more challenging. Achieving uniform material removal across a thick
workpiece may require longer processing times and careful process
optimization.

Design Limitations: Chemical machining is most effective for producing

two-dimensional or relatively shallow three-dimensional shapes. It may
not be well-suited for creating deep cavities, sharp corners, or structures
with significant height variations. Designing parts that require precise
control over internal features or complex three-dimensional geometries
can be more difficult to achieve with chemical machining.

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