ELECTRON BEAM

MACHINING

What is an Unconventional
Machining Process?
An unconventional machining process (or
non-traditional machining process) is a
special type of machining process in which
there is no direct contact between the tool
and the workpiece. In unconventional
machining, a form of energy is used to
remove unwanted material from a given
workpiece.

Why unconventional machining processes are used?

If materials (such as tungsten carbide, high speed steels, stainless steels,
ceramics etc.,) are machined with the help of conventional machining processes,
either the tool undergoes extreme wear (while machining hard workpiece) or the
workpiece material is damaged (while machining brittle workpiece).
This is because, in conventional machining, there is a direct contact between the
tool and the workpiece. Large cutting forces are involved and material is
removed in the form of chips. Huge amounts of heat is produced in the
workpiece. This induces residual stresses, which degrades the life and quality of
the workpiece material.
Hence, conventional machining produces poor quality workpiece with poor
surface finish (if the workpiece is made of hard and brittle material).
To overcome all these drawbacks, we use unconventional machining processes to
machine hard and brittle materials.

Introduction to Electron Beam Machining

Electron-beam machining (EBM) is a
thermal non-traditional process where highvelocity electrons concentrated into a
narrow beam are directed toward the work
piece, creating heat and vaporizing the
material. EBM can be used for very accurate
cutting or boring of a wide variety of metals.
Surface finish is better and kerf width is
narrower than those for other thermal
cutting processes.

Principle of Operation
When electrons impinge upon a solid material at a certain
speed, their kinetic energy is immediately translated into
thermal energy.
In removing material by electron beam machining, one of
two different mechanisms is employed: The material is
either totally evaporated, or it is simply melted. Then the
liquid phase is taken away by additional forces such as
centrifugal forces. In general, a combination of melting
and evaporating is used in such a way that generated
vapour pressure acts as additional force that assists in
ejecting the liquid material.

 The pulse interval, and thus the time of impact of the

beam on the workpiece is between 10ms and 10 ms.
The main task of process control is to choose suitable
beam parameters which allows the shape of the molten
volume to be controlled, as well as the position of
maximum temperature (the vapor source), so that the
liquid material is ejected completely and rapidly.
To obtain the machined shape required, sequences of
hundreds to thousands of pulses are necessary.
Reproducibility of the machining operations is normally
ensured by suitable computer control.

How EBM operates

The EBM beam is operated in pulse mode. This is achieved by
appropriately biasing the biased grid located just after the cathode.
Switching pulses are given to the bias grid so as to achieve pulse
duration of as low as 50 s to as long as 15 ms. Beam current is directly
related to the number of electrons emitted by the cathode or available in
the beam. Beam current once again can be as low as 200 amp to 1
amp. Increasing the beam current directly increases the energy per
pulse. Similarly increase in pulse duration also enhances energy per
pulse. High-energy pulses (in excess of 100 J/pulse) can machine larger
holes on thicker plates. The energy density and power density is
governed by energy per pulse duration and spot size.

Contd.
Spot size, on the other hand is controlled by the degree of
focusing achieved by the electromagnetic lenses. A higher
energy density, i.e., for a lower spot size, the material
removal would be faster though the size of the hole would be
smaller. The plane of focusing would be on the surface of the
work piece or just below the surface of the work piece. The
electron beam is generated by the potential difference
between the cathode and anode . Cathode is negatively
charged and anode is positively charged.

Equipmen
t
EBM equipment in construction is similar to
electron beam welding machines (see
electron beam welding). EBM machines
usually utilize voltages in the range of 150
to 200 kV to accelerate electrons to about
200,000 km/s. Magnetic lenses are used to
focus the electron beam to the surface of
the work-piece. By means of
electromagnetic deflection system the
beam is positioned as needed, usually by
means of a computer.
Note : Vacuums must be used to reduce
contamination, and minimize electron
collisions with air molecules. Because
work must be done in a vacuum, EBM is
best suited for small parts. The
interaction of the electron beam with the
work piece produces hazardous x-rays,
and only highly trained personnel should

Advantages of Electron beam

machining
There is no contact between the tool material and work piece material
Very small holes are also machined on different type of work piece
materials with high accuracy
Drilling is also done on the work piece material with a diameter of
nearly 0.002 inches
Drilling parameters are changed automatically during the machining
Distortions are not observed to the work piece material
This process is proficient in attaining high accuracy along with
repeatability.
Compare with the other process, formation of holes is easy with the
other process.

Disadvantages of Electron beam

machining
The cost of the equipment is very high
Metal removal rate during the process is low
Small cut operations are performed on the work piece
material with the help of EBM machine
Vacuum requirements boundaries the dimensions of the
work piece material
Need for secondary backing materials.

Applicatio
ns
Drilling:In drilling holes, the electron beam focuses on one spot and
evaporates material until it has completely penetrated the workpiece or is
switched of after a specified hole depth has been reached. Hole diameter
depends on beam diameter and energy density. If holes larger than the beam
diameter are required, theelectron beam is deflected electromagnetically in a
circular path of required diameter. Varying the amplitude of the voltage
generator connected to the electromagnetic deflection system can change
the diameter of the circular beam path. If extremely large holes are required,
the workpiece can be moved off center and rotated.
For example : Used for producing very small size holes like holes in diesel
injection nozzles, Air brakes etc

 Perforation:Electron beam machining is used widely to perforate

many materials including heat-resistant super alloys, plastics, and
textiles.
An important advantage of EB perforation is processs ability to drill
relatively small holes in thick materials. The process is normally
employed to produce holeswith depth-to-diameter ratios of about
10:1. This capability is employed effectively in the drilling of small
holes on the trailing edges of turbine blades, for example.
Milling:Applications in which EBM is employed to mill small profileshaped holes of less than 160 mm 2. The workpiece is held stationary
while the electron beam is programmed to cut the pattern.

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