Module3: Electro-chemical Machining & Chemical Machining

ELECTRO-CHEMICAL MACHINING
Introduction
ECM Process is based on the Faraday’s law of Electrolysis and reverse process of
electroplating as shown in the figure.
• In this process cutting tool having a shape which is mirror image of the finished workpiece
forms as cathode and workpiece forms as Anode.
• A small gap is maintained between the tool and workpiece, an electrolyte is pumped
through the gap.
• A low voltage of DC Power is used to cause electrolysis.
Faraday’s Law: Mass of substance altered at an electrode during electrolysis is directly
proportional to quantity of electricity transferred to that electrode.
Electroplating: uses electric current to coat an object with layer of metal.
Principle of ECM
• It involves Controlled Removal of Metal by Anodic dissolution in an Electrolytic Medium.
• Whenever 2 electrodes i.e. Anode workpiece is connected positive terminal and cathode
cutting tool is connected to negative terminal which is immersed in an electrolyte called
Nacl.
• Both anode and cathode is placed very close to each other without touching each other
about a gap of 0.5mm.
• When a voltage of 20DC is applied across the 2 electrodes the material removal at anode
starts.
• In ECM Material removal takes place at atomic level so it produces mirror finished surface.

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Let us understand chemical reaction

• As the potential difference is applied across the electrode the movement of ions starts in
between tool and workpiece. i.e. positive (+) ions move towards tool and negative (-) ions
move towards workpiece.
• At Cathode hydrogen ion take electrolyte & gets converted into Hydrogen gas
2H+ + 2e- -----→ H2
• In the same way iron atom comes out of Anode at workpiece.
Fe ----→ Fe++ + 2e-
• Within the Electrolyte, sodium ion combines with hydroxyl ion (OH-) and form Sodium
hydroxide NaOH.
• Similarly, Ferrous ion combines with Chorine & form ferrous chloride.
Fe2+ + 2Cl- ---→ FeCl2
• Also, iron combines with hydroxyl ion form Iron Hydroxide and material removed from
the workpiece acts as Sludge.

Elements of ECM Process

The Elements of ECM Process include:
a) Cathode tool: having a shape similar to that desired in the workpiece metal
b) Anode Workpiece: which is good conductor of electricity.
c) DC Power source: sufficient capacity so that high current densities can be maintained
between tool and workpiece.

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d) Electrolyte: a liquid that carries electric current and also acts to complete the circuit
between the tool and workpiece metal.
Need of ECM
• ECM process usually preferred for Mass Production.
• ECM used for machining Extremely Hard-Material and for machining electrically
conductive materials.
• Also, preferred when Materials that are difficult machine using conventional methods.

ECM Equipment
ECM Cannot Be Considered as general purpose machine. It is Completely tool oriented. Here
tooling has to be select first.
Equipment Mainly Consists of following Components
1. Tool
• Tool also called as Electrode Forms (-)ve terminal of the electrical Circuit.
• Shape of the tool must be Similar to the Shape of the finished workpiece.
• The Material Selected by the tool Should be easily machinable.
• Good stiffness to exhibit High electrolyte pressure.
• Good electrical &thermal conductor
• Usually Al, bronze, brass, Copper. Stainless-Steel, Reinforce Plastic are used as tool-
Material.
2. Electrolyte
• It is the Working medium and performs the bellowing functions.
• It Complete the electrical Circuit between the tool & workpiece.
• It acts of Conductor to carry current.
• It carries away the products of machining from the workpiece in the form of slag.
• It carries the heat generated machining Zone.
Commonly used Electrolyte in ECM Electrolyte Should possess Following characteristics
➢ High electrical Conductivity
➢ Low viscosity
➢ High specific heat
➢ Chemical stability

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➢ Non-Corrosive & Non-toxic.

➢ Inexpensive & easily available
➢ Resistance to Formation of Film on the workpiece.
3. Filter
• Filters are placed in the System to Clean the Contaminated electrolyte, So that Fresh flow
of electrolyte to Machining area all the time.
• A wire mesh Filter of 75µm Size mode from Monel metals used.
• It should be cleared once in a 30 hours.
4. Power Supply
• Ac Power available from Mains is Converted into low voltage DC by a Step-down
transformer and rectifier.
• Current in the order of 1000-40,000 Amp is Generally used for Machining & voltage range
from 3-25V.
Note: Apart from the above parts of ECM equipment Consists of Pump. Storage tank, valve and
piping are also necessary.
ECM Operation

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Module3: Electro-chemical Machining & Chemical Machining

• Tool having a shape, similar to that finished workpiece is fed towards workpiece,
maintaining a small gap approximately 0.25mm between them.
• This is accomplished by utilizing the servo-drive on the feed-axis.
• High current, low voltage DC Power supply connected between Tool and workpiece.
• Tool is connected to the negative terminal and workpiece is connected to the positive
terminal.
• The electrolyte is pumped at a high pressure through the small gap between tool &
workpiece thus providing a necessary path for electrolysis.
• When the current is passed dissolution of the workpiece occurs, meanwhile flowing
electrolyte washes the metal ions away from workpiece before they have a chance to plate
on the tool.
• As the tool moves down to maintain a constant gap the workpiece is machined to the same
as that of the tool.
Chemistry of ECM Process
Figure shows chemical reactions in ECM of a low-carbon steel workpiece with Nacl solution in
water as Electrolyte.

• When a suitable potential difference is applied, electrolyte undergoes ionic dissolution.

Nacl ----→ Na+ + Cl-
H2O --→ H+ + OH-
• Similarly, as the potential difference is applied across the tool and workpiece. The positive
ions from Fe++ from workpiece move towards cathode tool & reacts with hydra-oxyl ions
(OH-) to form ferrous hydroxide Fe(OH)2.
Fe + 2H2O ----→ Fe(OH)2 + H2
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Module3: Electro-chemical Machining & Chemical Machining

• Also, within the electrolyte iron ions would combine with chloride ions from iron-chloride
(FeCl2). Both FeCl2 and Fe(OH)2 get precipitated in the form of Sludge.
• The process continue in this manner the workpiece gets gradually machined & precipitated
as a sludge.
Note: only H2 is evolved at the cathode & hence the shape of the tool remains unaltered
during machining process.

Process Parameters of ECM

Following are the critical parameters which affect MRR & Surface Finish.
1. Current Density
• Current density is nothing but the current that can be passed into a square inch of work
area.
• Figure shows relationship between current density & MRR.
• At low current density MRR is small.
• ECM used for particular application must have current density of about 50-1500 A/in2.

2. Tool Feed-rate – rate at which tool moves through the material during machining
• Tool federate is directly proportional to current density.
• If the federate is increased, the electrical resistance of the tool-work gap reduces to allow
more current to flow resulting in High MRR.
• Surface finish and accuracy also improved.
3. Gap b/w workpiece and Tool
• Tool & w/p are kept so close together to encourage efficient electrical Transmission.

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Module3: Electro-chemical Machining & Chemical Machining

• Small gap results in high Casement density hence MRR increases.

• Size of the gap varies from 0.25-076mm
• A gap Size of 0-25mm is often user.
4. Velocity of Electrolyte Flow
• Electrolyte flow is usually b/w 15-60 m/s.
• If Electrolyte flow is low, i.e. heat & by product of the reaction- (H2, bubble, Sludge) build
in the gap causing Non-uniform MRR.
• If electrolyte flow is High... Will Cause Cavitation leads to Non-uniform MRR.
5. Type or electrolyte, Concentration & Temperature
Type of electrolyte depends on the tool and workpiece Material
For example:
a) Nacl: - is so cheap & possess, good conductivity but Corrosive hence Cannot be Preferred on
Tic & Molybdenum materials.
b) NaNO3: it is popular due to less Corrosive but does not Produce good Surface Finish as Nacl.
• it is expensive than Nacl
• it is Preferred in machining for machining of Al & Cu.
6. Electrolyte concentration
• Electrolyte in water at various concentration affects Surface finish Produced.
• At Low Concentration i.e. (less water More Nacl) decreases. Equilibrium Machining gap
resulting in better SF & tolerance Control.
7. Electrolyte temp
• Electrolyte temp Seriously affects overcut.
• Power loss in the electrolytic reaction increases in temp of the electrolyte.
• Heat must be Carried away from cutting area So as to maintain Stable & Steady Condition.
• Low temp of electrolyte is Conductive to better Surface Finish & tolerance.

Process Characteristics
1. Metal Removal Rate
• MRR in ECM depends on Feedrate & Current Density.
• For High Machining rate high current density is essential.

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• But current should not be so high it Produce excess heat in the tool, Leads to decomposition
of electrolyte.
➢ Current density order of 1.5-4.5 mA/m2
• In normal working condition MRR upto 0.08µm3/Sec is possible.
2. Surface Finish
Surface finish in the order of 0.3 to 1.9µm at Front gap area and 5 µm at side gap area.
Surface finish is affected by
➢ Current density
➢ Feed rate
➢ Gap Size
➢ Temperature
➢ Flow of electrolyte
➢ Micro-Structure of workpiece.
3. Accuracy
• Dimensional tolerance obtained in ECM about ±0·12mm at Front and ± 0.25mm at Side.
• With Suitable process Control it is possible to achieve tolerance as close as 0.025mm
• It is difficult to Machine (Internal Radius deep than 0.8mm.
• External radius less than 0.5 mm can be easily machined
o Taper -0.001mm
o Overcut - 0.5mm
o Corner radius - 2.6mm.
Tool and Insulation Materials
Tool materials
In general, any Electrically conducting materials can be used as a Tool. Therefore, tool materials
should possess following characteristics:
• Non-corrosive in nature
• Easily machinable
• Good thermal conductivity
• Highly Stiffness
• High Electrical Resistivity.
Some commonly used tool materials are:

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• Stainless steel
• Brass
• Copper
• Titanium and Tungsten.
Insulation Materials
It is an important parameter in controlling exposed surface, machining area and current
density.
• Usually, insulation materials applied on the tool surface either by spray coating or
dipping.
• Commonly used insulation materials are Teflon and epoxy.
• Proper bonding & thickness of insulation is usually (0.5mm) to obtain a good film.

ECM Tooling Technique

The tool used in the ECM process is approximately Mirror image of the Shape to be
machined in the w/P. Hence tool is Properly designed in Size & shape.The different tooling
techniques for Producing Simple hole is illustrated in the figure.
Tool
Electrolyte + How
1. Round-Tool
• This is a normal cylindrical tool, leading edges are sharp & no-shank insulation.
• This type of tool instead of Producing round hole, it produces a hole with Small taper.
• This is because the Complete Surface area of the hole is completely machined by
Electrolyte.
• This to due to lack of insulation on the sides of the tool Causes unwanted Machining of the
work lead to less in Accuracy.

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2. Round Tool with insulation

• In this type Same round tool-Shank -insulated on it sides.
• Such a tool technique eliminates the problem of taper.
• However, this type of Tool still not Correct in design, because electrolyte become turbulent
as it Passes around Sharp Corner of the tool.
• Leading to arcing & Possible Shorting at Corners of the tool Tool.

3. Tool with Radiused Edge

• In this type. Circular Radius tip is brazed at leading edge of the tool.
• This encourages the uniform Electrolyte flow around corners and reduces the effect of
turbulence which produces good surface finish.

4. Tip Replaceable Type

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• In another design Tip is extended beyond the tool-Shank.

• This helps in breaking up of the flow as it Passes through the radiused Corner.
• There by minimizing the effect of any Stray Current of electrolyte which like to cause
additional Machining over already machined surface.
Note: In all the above design electrolyte flow from inside tool, then around cutting edge & up
through the hole.
5. Round Tip flush with Shank

• In another design tip flush with Shank and Radiused Comer.

• Along with a combination of reverse flow, this design gives best result of & negligible
Taper.
• This design used for Precision work.
Advantages of ECM
• Accurate shape with good surface finish can be obtained.
• Machined surface is stress-free and high surface finish.
• No physical contact between tool and workpiece. Hence no tool wear and also no burrs are
used.
• Capable of machining metals and alloys irrespective of their strength and hardness.
• Metal removal is due to anodic dissolution. Hence thermal effect on the workpiece.
• Process can be easily automated.
• Several tools could be connected to a cassette to make many cavities simultaneously.
• Suitable for mass production applications.
Disadvantages of ECM
• Suitable only for conducting materials.

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• Space and floor requirements are higher than conventional machines.

• High electrical power is consumed.
• Post-machining and cleaning is a must reduce the corrosion of the workpiece.
• Limited to mass production due high tooling and setup cost.
• No environmentally friendly. The sludge produced in large amounts need to be disposed
off.
• Frequent maintenance of equipment is necessary in order to avoid corrosion of parts.
Applications
• Industrial sector utilizing ECM technology include tool and die making industries,
automotive, aerospace, power generation, oil and gas industries.
• Specific application of ECM include facing and turning complex three-dimensional
surfaces, deburring, grinding, honing, cutting-off, die-sinking, profiling, multiple hole
drilling etc.,
Electro-chemical Grinding (ECG) - is also Called as Electrolytic Grinding.
ECG is a Process in which Material Removal of Electrically Conducting work-Material is takes
place through Combined effect of Electro-chemical process and Mechanical erosion of abrasive
particle on the work-Materials.

Construction
• Process Maker use of Metallic Grinding Wheel embedded with abrasive particle Such as
Al2O3 or diamond set in a Conducting bonding material.

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• Here Grinding wheel acts as Cathode and workpiece as Anode.

• Electrolyte usually NaNo3 in water is supplied through Nozzle the gap between Grinding
wheel and workpiece. Such that it carries through the Cutting process there by resulting in
ECM action.
• Contact wire brush are used in the spindle of the grinding wheel to supply current into the
Spindle from which flows into the Grinding wheel.
Working
• When a DC voltage of about 5-15V is applied between Workpiece & grinding Wheel, a
suitable Current density is Created.
• There by Removing Material from the Work piece Surface by ECM action and abrasive
action of the grinding wheel.
• Nearly 10% of workpiece volume removed by abrasive action of the wheel and
Remaining: 90% by ECM action.
Note: W/P Metal goes into the Solution as Metal ions (anodic dissolution) & bubbles of H2
generated at the wheel.
Advantages of ECG
• Ability to grind any electrically conductive material regardless of Hardness.
• MRR are 5 to 10 times greater than broaching, milling or conventional grinding.
• Frequent grinding wheel dressing is unnecessary.
• Longer wheel life and low wheel cost per volume of material removal.
• Accuracy and surface finish are comparable.
• High production rates are possible.
• No distortion of thin and fragile parts.
• Workpiece is not subjected to overheating.
Disadvantages of ECG
• Workpiece must be electrically conductive.
• High Equipment cost.
• Not suitable for grinding low hardness metals.
• Post cleaning of work and equipment parts is necessary in order to avoid corrosion effect
of the electrolyte used.

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• The space between the grinding wheel and workpiece must be filled with electrolyte at all
times during ECG. Failure to do this, reduces MRR and causes needless wear of grinding
wheel.
• Sharp corners are difficult to obtain.
• High Maintenance

Application of ECG
• Wide Application of ECG lies in the grinding of carbide cutting tools due to its rapid metal
removal rate on hard and rough materials.
• ECG provides savings of about 75% in wheel cost and about 50% in labour costs in
grinding tungsten carbide.
• Absence of burring, over heating permits thin and fragile parts such as honeycomb thin
walled tubes and skins hypodermic needles and similar such parts.

Electro-Chemical Honing (ECH): is a Modification of Conventional Honing.

In ECH process Material from electrically Conducting Workpiece is Removed by
Combined action of Anodic dissolution of work-Metal (ECM) & Mechanical abrasive action.
Construction
• Process Makes use of a hollow Stainless steel tool as Cathode & workpiece as Anode.
• Tool is rotated & reciprocated on a rigid Spindle for precise Metal removal from
Cylindrical hole of workpiece.
• The bonded abrasive stone protrude/extended from at least 3 locations around
circumference of tool.
• Length of the Honing Stone is half of the length of bore to be honed on the wp.
• Stone are Non-Conductive & assist ECM action.

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Working
• Initially Honing Stones are made to extend/protrude by a small distance of 0.2mm from
tool body & establishing gap between workpiece through which electrolyte flow.
• A Suitable electrolyte such as Nacl/NaNO3 is supplied under pressure through holes
provided in the tool body and then into tool and workpiece gap.
• As the cutting tool rotates and reciprocates in the workpiece hole material removed by
combined action of ECM & abrasive action of stones.
• The process continues until required finish is obtained.
Advantages of ECH
• Ability to hon/grind any electrically conductive material regardless of hardness.
• Burr-free action.
• Surface finish and accuracy are far comparable to conventional honing.
• Reduced noise and distortion.
• High production rates are possible.
• Machining is primarily by electrochemical dissolution and hence results in stress-free
machining and less low heat generation compared to conventional Honing.
Disadvantages of ECH
• Workpiece must be electrically conductive.
• High equipment cost
• High maintenance
• Post cleaning of work and equipment parts is necessary in order to avoid corrosion effect
of electrolyte used.

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Module3: Electro-chemical Machining & Chemical Machining

CHEMICAL MACHINING
Introduction
In Chemical machining process, Chemicals & acids are employed remove small amount of
Material from the workpiece. This is the basic idea behind developing the CHM Process.
Chemical Machining (CHM) is a well-Known Non-Traditional Machining Process.
Definition
"Chemical Machining is the Controlled Chemical dissolution of the Work-Material by Contact
with a Strong acid /alkaline Chemical reagent.
• It is the oldest NTM method used to Shape Copper with Citric acid in Ancient Egypt at
2300 BC. i.e. Working Principle of CHM is based on "Chemical etching"
Principle of Chemical Machining
CHM is a process used to remove Material from the workpiece by chemical dissolution in a
Controlled Manner. Also, Working Principle of CHIM is based "Chemical etching"

• Here part of the Workpiece Material where Material is to be removed is brought Contact
With Strong Corrosive chemical Called Etchant.
• The Etchant react with Work-Material in the area to be cut & Cause Solid work Material
to be dissolved in it.
• Therefore, Material is removed by the Chemical attack of the Etchant.
• Portion of the W/P Material where Material is need not to be remove is Protected from
Chemical attacks by special coating caused "Maskants".
• Nearly all Materials from Metals to Ceramics Can be machined with CHM.

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Need For CHM

• Hard & difficult to shape metals Cannot be easily Machined by " Conventional Machining
Methods.
• Work-parts with Complex Configuration or delicate parts fails to withstand force of
Cutting tool.
• Some NTM process they are not Economical due to High Capital & tooling Cost.

Elements of CHM Process

1. Etchant
• Etchant are acid/alkaline solution Maintained with in a Controlled range of chemical
Composition & temp.
• The Workpiece Material to be removed is Sprayed/immersed in a Suitable etchant.
• The Etchant react with Work-Material in the area to be cut and dissolved in it.
• The various Etchants are available for Machining different Material is listed below.

Factors which affect the Selection an etchant for a given Component are:
a) Type of work piece Material that is being etched.
b) Depth of etch required
c) Rate of Metal Removal
d) Surface finish.
e) Type of Maskant.

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f) Un-harmful to human operators ( i.e. etchant Should Maintain air quality and avoidance of
Environmental Problem)
g) Availability & low cost.
h) Ability to Regenerate etchant Solution & readily neutralize o dispose waste product.

2. Maskant
• Maskants are Rubber or Polymer based Materials generally used to protect W/P Material
where Chemical dissolution is not needed.
• Maskants Can be applied on workmaterial by various methods like dip, brush, Spray, roller,
electroplating or adhesive bonding or tape.
• Sometimes Multiple Coats of Maskants are frequently used increase etchant resistance to
avoid formation of pinholes on Machined Surface.
Type of Maskant to be Selected for Machining based on the following factors:
➢ Chemical resistance required
➢ Be inert to the chemical reagent
➢ Be tough to withstand handling.
➢ Able Adhere well to the workpiece Surface.
➢ Remove easily & inexpensively after etching.
➢ Able to withstand heat generated by etching.
➢ Availably & low cost.
Types of Chemical Machining Process
1. Chemical Blanking Process: used Cutting Parts from thin sheet Metals.
2. Chemical Milling Process: used for Cutting Material from thick workpiece.

Chemical Blanking Process

It is the Process of Producing a part from thin Sheet Metal or Strip by chemically etching
periphery of a desired shape. The material is removed by chemical dissolution.
Application include are: burr free etching of printed circuit board, decorative panel, thin sheet
metal stamping, complex & small shape parts.
Processing steps as discussed below:
1. Workpiece pre-cleaning process
• Surface of the Workpiece is Cleaned thoroughly. i.e. degreased/Pickled by acid/alkali.

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• In order to remove dust, oil, grease or any foreign Substance from Workpiece so as to
Produce a good adhesion of Masking Material.
• Material is allowed to dry.
2. Masking
➢ Masking involves Covering portion of the workpiece where material need not to be
removed by the chemical action of etchant.
➢ Maskant is applied on the Workpiece by various Methods like Dip, Brush. Spray. Roller
electro-Coating & as well as adhesive tape.
➢ Usually Polymer /rubber or any other Material is selected based on workpiece Marial.

3. Etching
• Removal of Material from the Workpiece is takes place by etching Process.
• workpiece Material is either Sprayed Continuously With Echant like FeCl3 on those
portion where Material is need to remove or immersed in a tank of agitated Etchant.
• Etchant chemically attacks on those portion where not masked.
• Erosion of Workpiece Material takes place both in-ward & Laterally from unmasked
Surface as shown in fig b to d.
Note: - Work-Material is converted into Metallic salt which then dissloved & Carried by
etchant Solution.

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4. De-Masking
• when etching is completed, Mask is removed either by Chemical/Mechanical means.
• Any etchant on the Work-Material is need to removed by either washing /cleaning by
cold water.
• Deoxidizing bath may also require in order to remove oxide film left on the Surface of
workpiece.
Chemical Milling or Contour Machining
It is a Process used to produce shapes by chemically etching selective portion of Material
from large Surface area of work-Metal.
• Main purpose is to produce Shallow Cavities With Complex Profiles on Plates, sheets &
Forging generally overall reduction of Weight.
Steps involved
1. Work-piece Pre-cleaning
• Surface of the Workpiece is Cleaned thoroughly. i.e. degreased/Pickled by acid/alkali.
• In order to remove dust, oil, grease or any foreign Substance from Workpiece so as to
Produce a good adhesion of Masking Material.
• Material is allowed to dry.

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2. Masking & Scribing Mask

• Masking involves Covering the Portion of the Work-Material Where material is need
not be removed by Chemical action of etchant.
• Masking With adhesive tape or Paint is a Common Practice, Also elastomers like
(Rubber & neoprene) and Plastics like (PVC, Polyethylene, Polystyrene) are used.
• Since it is very difficult to apply Maskants on Small Surface, initially applied on large
Surface area & then Scribed or cut by Sharp knife followed by carfeul Peeling of the
mask from Selected area to be etched
3. Etching
• Un-masked (exposed) Surface of the Work- Material are Machined chemically With
Etchants
• Etchants is carried out by immersing work-Material in a tank of agitated etchant.
• Process is Carried out at Higher temperature depending on etched material.
• Temperature Control & Stirring during chemical Milling is important in order to obtain
uniform depth from the material to be removed.
• Erosion of the Work-Material take place from unmasked surface.
• Here work Material is Converted into Metallic Salt, which is then dissolved & Carried
away in etchant Solution.
4. De-Masking
• when etching is completed, Mask is removed either by Chemical/Mechanical means.
• Any etchant on the Work-Material is need to removed by either washing /cleaning by
cold water.
• Deoxidizing bath may also require in order to remove oxide film left on the Surface of
workpiece.
Process Characteristics of CHM
Various Parameters involved in CHM are:
• Type of Etchant & it's Concentration.
• operating Temperature & Circulation.
• Also affected by Maskant & it's application
Above parameters have direct impact on Accuracy Surface finish and MRR.

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1. Metal Removal Rate (MRR)

• MRR or etching rate Mainly depends on type of etchant used.
• Etchants that remove metal at faster rate have many Side effects.
➢ Reduction in Surface finish
➢ Increased under cut
➢ Higher Heating
➢ Attack on bond b/w Maskant & work Surface.
• Etchant rate is usually limited b/w 0.02 to 0.04 mm/min.
2. Accuracy
• Accuracy obtained CHM depends on under Cut produced.
• undercut per edge & radius approximately equal to depth of cut as shown in the figure.
• Allowance for undercut is Provided in the design itself.
• Tolerance on Depth of Cut increase when machining larger depth at High Machining rate.
• under optimum Condition of Time, temperature & Solution accurately ranges from ±
0.01mm.
• Al & Mg alloy Can be controlled more closely than steel, Nickel or Titanium.

3. Surface Finish
• Machining Rate generally affects the Surface roughness.
• Generally Slow-etching will produce a Surface Finish Similar to original Surface.
• Also, Surface roughness influenced by initial work-piece roughness.
➢ For Low Machining depth of less than 200µm ≈ 0.02mm Surface roughness
Sharply increases as the depth of Cut increases.

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➢ Typical Surface roughness of 0.1 to 0.8 µm Can be achieved depending on initial

roughness.
• However special condition, roughness in the order of 0.025 to 0.05µm is also possible.

Advantages of CHM
• Many work parts can be etched simultaneously.
• No burns are found i.e. high surface finish.
• No stress is introduced to the workpiece.
• Low Capital investment.
• Design changes can be implemented quickly.
• Tooling costs are minor.
• Less skilled operator is needed.
• Good surface quality.
Disadvantages of CHM
• Limited depth of cut.
• Difficult to produce sharp radius.
• Handling and disposal of chemical could be troublesome.
• Hydrogen absorption leading to embrittlement,
• Metallurgical homogenous work surface is required best machining results.
• Fillet radius is fixed by the depth of cut.

Applications of CHM
• Shallow cuts in large thin sheets for weight reductions. In pre-formed aerospace
components is a major application of chemical machining.
• CHM is used to thin out walls, webs and ribs of parts that have been produced by forging,
casting, or sheet metal forming.
• Used for process applications related to improving Surface Characteristics like elimination
of decarburized layer from low alloy steel forgings.
• Engraving highly intricate details on any metal piece. is another important application of
chemical machining.

Prof. Krishna Prasad S, Assistant Professor Dept. of ME, MIT Mysore Page 23