Chemical Machining Flashcards
Chemical Process Mechanism
- Cleaning
Create a clean surface for uniform material removal when etching - Masking
Application of a protective and chemically resistant coating called maskant or resist to certain parts of the workpiece surface - Etching
Immersing the part in an etchant (acid or alkaline) which dissolves material from the unmasked workpiece surface - Demasking
Maskant is removed from the workpiece and any residues washed off
Variations of Chemical Machining ?
Chemical Milling
Chemical Blanking
Photochemical Milling
Applications of Chemical Machining?
- Alternative to laser cutting and fine blanking thin foils and sheets and to conventional milling, EDM and ECM for cavities and forms
- Weight reduction by thinning out walls, ribs etc. made by forging, casting or sheet metal forming
- Aircraft industry – wings, fuselage panels for weight reduction
- Electronics – printed circuit boards and intricate designs, semiconductors wafers
- Thermochemical Deburring
Advantages of Chemical Machining?
Low investment costs for tooling and equipment
Almost all metals and alloys can be manufactured, including
hardened materials
No distortion as no
thermal or mechanical stress
No burrs
Good for low volume production and one-offs
Short manufacturing lead times
Disadvantages of Chemical Machining?
Limited to metals only
High volume and automation may become expensive
Production rates are slow compared to conventional
machining operations
Not suited for sharp profiles (only round internal and external
corners)
Environmental impact with the disposal of chemicals
High risk to health and safety
Safe handling of corrosive chemicals and fume distraction can
be problematic
What are the three process mechanism of applying maskant?
Cut & Peel
Screen resist (silk screening method)
Photographic resist
