Electron beam machining:
INTRODUCTION:
Electron beam machining is a thermal process used for metal removal
during the machining process. In EBM a high velocity beam of
electrons are used to remove the metal from the workpiece.
Principle of EBM :
When the high-velocity beam of electrons strikes the workpiece, its
kinetic energy is converted into heat. This concentrated heat raises
the temperature of workpiece material and vaporizes a small amount
of it, resulting in the removal of material from the workpiece.
Construction and Working of Electron Beam
Machining :
Construction of EBM :
• The schematic arrangement of Electron Beam Machining (EBM) is
shown in Fig.
• It consists of an electron gun, diaphragm, focusing lens, deflector
coil, work table, etc.
• To avoid collision of accelerated electrons with air molecules, a
vacuum is required. So, the entire EBM setup is enclosed in a
vacuum chamber, which carries a vacuum of the order 10-5 to1O-6
mm of mercury. This chamber carries a door, through which the
workpiece is placed over the table. The door is then closed and
sealed.
• The electron gun is responsible for the emission of electrons, which
consists of the following three main parts.
1. Tungsten Filament — which is connected to the negative terminal
of the DC power supply and acts as the cathode.
2. Grid cup – which is negatively based concerning the filament.
3. Anode – which is connected to the positive terminal of the DC
power supply.
• The focusing lens is used to focus the electrons at a point and
reduces the electron beam up to the cross-sectional area of 0.01 to
0.02 mm diameter.
• The electromagnetic deflector coil is used to deflect the electron
beam to a different spots on the workpiece. It can also be used to
control the path of the cut.
Working of Electron Beam Machining :
• When the high voltage DC source is given to the electron gun, tungsten
filament wire gets heated and the temperature rises up to 2500°C.
• Due to this high temperature, electrons are emitted from tungsten
filament. These electrons are directed by a grid cup to travel towards
downwards and they are attracted by the anode.
• The electrons passing through the anode are accelerated to achieve high
velocity as half the velocity of light (i.e., 1.6 x 10 8 m /s) by applying 50
to 200 kV at the anode.
• The high velocity of these electrons are maintained until they strike the
workpiece. It becomes possible because the electrons travel through the
vacuum.
• This high-velocity electron beam, after leaving the anode, passes through
the tungsten diaphragm and then through the electromagnetic focusing
lens.
• Focusing lenses are used to focus the electron beam on the desired spot
of the workpiece.
• When the electron beam impacts on the workpiece surface, the kinetic
energy of high-velocity electrons is immediately converted into the heat
energy. This high-intensity heat melts and vaporizes the work material at
the spot of beam impact.
• A suitable viewing device is always incorporated with the machine. So, it
becomes easy for the operator to observe the progress of the machining
operation
Advantages of EBM :
Electron beam machining has the following advantages :
1. It is an excellent process for micro finishing (milligram/ s).
2. Very small holes can be machined in any type of material to high
accuracy.
3. There is no mechanical contact between the tool and the work
piece.
4. It is a quicker process. Harder materials can also be machined at a
faster rate than conventional machining.
5. The physical and metallurgical damage to the work piece is very
less.
6. This process can be easily automated.
7. Extremely close tolerances are obtained.
8. Brittle and fragile materials can be machined.
Disadvantages of EBM: Limitation of EBM
1. The metal removal rate is very slow.
2. The cost of equipment is very high.
3. It is not suitable for large work pieces.
4. High skilled operators are required to operate this machine.
5. High specific energy consumption.
6. Vacuum requirements limit the size of the workpiece.
7. It is applicable only for thin materials.
Application of EBM :
1. EBM is mainly used for micro-machining operations on thin
materials. These operations include drilling, perforating, slotting,
and scribing, etc.
2. Drilling of holes in pressure differential devices used in nuclear
reactors, aircraft engines, etc.
3. It is used for removing small broken taps from holes.
4. Micro-drilling operations (up to 0.002 mm) for thin orifices, dies for
wire drawing, parts of electron microscopes, injector nozzles for
diesel engines, etc.
5. A micromachining technique known as “Electron beam lithography”
is being used in the manufacture of field emission cathodes,
integrated circuits, and computer memories.
6. The process parameters directly affecting the machining characteristics
in Acceleration voltage
Electron Beam Process – Parameters
The process parameters, which directly affect the machining
characteristics in Electron Beam Machining, are:
• The accelerating voltage ----10-150kV
• The beam current ------ as low as 200 μamp to 1 amp
• Pulse duration---------- 50 μs to as long as 15 ms
• Energy per pulse-------- in excess of 100 J/pulse
• Power per pulse -------- 30W-100kW
• Lens current
• Spot size------------------ 10 to 100 um
• Power density
7. • Beam current
8.
9. • Pulse duration
10.
11. • Energy per pulse
12.
13. • Power per pulse
14.
15. • Lens current
16.
17. • Spot size
18.
19. • Power density
