Non Traditional Machining Processes

MIME - 6980

Electron Beam Machining

Presented by,

Abhijit Thanedar
Naga Jyothi Sanku
Pritam Deshpande
Vijayalayan Krishnan
Vishwajeet Randhir

Introduction - A Brief History

Development of EB technology is closely related
with advances in vacuum engineering and electron
optics
In 1905, Marcello von Pirani successfully melted
Tantalum
In 1938, magnetic lens were introduced to focus EB
It was only in 1965, all techniques were put
together and secured a place in production
processes list.

Classification of NTM processes

Classification based on the energy source

Mechanical
Electro-chemical
Chemical
Thermo-electric

EBM uses Thermo-electric Energy.

ELECTRONS
HIGH
VOLTAGE
VAPORIZATION

EDM

RADIATION

THERMOELECTRIC
ION STREAM

HOT GASES

ELECTRON
BEAM

AMPLIFIED
LIGHT

LASER

IONIZED
MATERIAL

ION BEAM
PLASMA ARC

NON TRADITIONAL MACHINING

PROCESSES - THERMOELECTRIC

GENERATION OF ELECTRON BEAM:

The electron beam is formed inside an electron gun,
which is basically a triode and consists of:
A cathode which is a hot tungsten filament
emitting high negative potential electron
A grid cup, negatively biased with respect to
filament , and
An anode at ground potential though which
the accelerated electrons pass

Energy Conversion at the point of action

electrons are accelerated in the electrostatic field of the beam
source to attain a kinetic energy,
E = e UB
the kinetic energy absorbed by the electrons during their
trajectory through the accelerating field is
E = (me0/2) ve2 (1 + 3 ve2/4c2 + 5 ve4/8 c4 +)= e UB
Where me0 is the electron rest mass, v e is the electron velocity, c is the
velocity of light and e is the electron charge.

Relation between velocity and acceleration voltage

VELOCITY OF LIGHT
3
8

10

Ve (m/s)

10

Ub

10

ELECTRON BEAM
e=EU

HEAT RADIATION
E=hv
X-RAYS
E=hv eU

BACKSCATTERED ELECTRONS

SECONDARY ELECTRONS
E50eV
THERMIONIC ELECTRONS
E<1eV

SURFACE TEMPERATURE (T)

RANGE OF ENERGY
CONVERSION

BEAM ACTION ON IMPINGEMENT ON MATTER

Machine Tools
The three major subsystems that make up an
electron beam machining system are
power supply,
electron beam gun, and
the vacuum system.

Modern EBM Drilling Machine

POWER SUPPLY
Pulsed DC
Voltage range up to 150 kv to accelerate
electrons
Systems capability can go as high as 12 kw
high-voltage sections of the power supply
are submerged in insulating dielectric oil

ELECTRON GUN
gun is designed to be used exclusively for
material removal applications and can be
operated only in the pulse mode
It has a cathode, bias electrode, anode,
magnetic coil/lens (to converge the beam),
variable aperture, 3 final magnetic coils
(used as magnetic lens, deflection coil, and
stigmator) and rotating disc.

Gun Types
2 electrode gun

3 Electrode Guns

Modified 3 Electrode Guns

Rogowski gun

Telefocus gun

Four Electrode Array gun

High-perveance guns
Pierce gun

Guns with Curved Electron Trajectories

Guns with Concave Emmiting

Surface and center bore in cathode

Beam Guidance

ELECTRON
GUN

WORK
BEAM
GUIDANCE CHAMBER
SYSTEM

SOURCE

FOCUSING DEFLECTION

MATHEMATICAL MODEL:
Energy of Electrons:
The kinetic energy of the electrons can be written as:
K.E.=Ee=1/2 mV2.
Where,
m= mass of electron.
e= charge on electron.(joules)
E= voltage.
V= velocity of electron.(cm/sec)

Number of electrons per second (N):

N= I n.
Where ,
I= beam current.
n= electron per second per amp current.

Total Power :
P= E I
Energy Required to vaporize Workpiece:
Material removal rate :
G = nP/W.(cm3/sec)
Where:
P = Power.(watts)
n= cutting efficiency.
W= Specific energy required to vaporize metal. (joules/cm3)
W=[C(Tm-20)+C(Tb-Tm)+Hf+Vv]
Where:
C= Specific Heat, Tm = Melting temperature
Tb = Boiling temperature, Hf = Heat of fusion,
Hv = Heat of vaporization

MRR Vs POWER

TUNGSTEN

IRON
TITANIUM

POWER
ALUMINUM

METAL REMOVAL RATE

Parameter Zones

Thermal processing of solids.

Thermal processing of thin films
Non thermal processing

Parameters and their influence

Power density

Drilling of all materials

FILAMENT
BIAS CUP

ANODE

FLOW OF ELECTRONS
FOCUS COIL

DEFLECTION COIL
METAL VAPOR
MOLTEN METAL

HOLE

Parameters for drilling various materials

Thickness

Hole

Drilling speed

Acclerating

Avg beam

Pulse

Pulse

(in)

diameter (in)

(Sec)

voltage(kv)

current

width

Frequency

(microamp)

(micro

(cps)

sec)
0.010

0.0005

<1

130

60

3000

0.030

0.012

30

125

60

80

50

0.010

0.001

<1

140

50

20

50

0.040

0.005

<1

140

100

80

50

0.40

0.005

<1

140

100

80

50

0.100

0.005

10

140

100

80

50

0.016

0.003

<1

130

100

80

50

0.125

0.001

<1

140

10

12

50

Examples of EBM Drilling

Examples of EBM Drilling

Examples of EBM Drilling

Examples of EBM Drilling

Hole Diameter Vs Pulse Charge

Depth & Diameter Vs Beam Current

Depth of Cut, Milling Width Vs Input Energy

Relation between material thickness s, hole diameter

dB, and perforation rate ns

1
db
.1

0.01
S