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    Electron Beam Machining

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    Abhishek Kumar
    Electron beam machining uses a stream of electrons focused into a small diameter beam to locally heat and vaporize material. The process requires a vacuum system and machining chamber to generate and direct the electron beam without collisions. Key elements of an electron beam machining system include the electron beam gun to produce and focus the beam, a high voltage power supply, and computer controls to adjust process parameters like beam current, pulse duration, and beam positioning. Electron beam machining can drill small, high aspect ratio holes in both conductive and non-conductive materials without applying mechanical forces.

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    Electron Beam Machining

    Uploaded by

    Abhishek Kumar
    574 views18 pages
    Electron beam machining uses a stream of electrons focused into a small diameter beam to locally heat and vaporize material. The process requires a vacuum system and machining chamber to generate and direct the electron beam without collisions. Key elements of an electron beam machining system include the electron beam gun to produce and focus the beam, a high voltage power supply, and computer controls to adjust process parameters like beam current, pulse duration, and beam positioning. Electron beam machining can drill small, high aspect ratio holes in both conductive and non-conductive materials without applying mechanical forces.

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    ELECTRON BEAM MACHINING.ppt

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    Electron beam machining uses a stream of electrons focused into a small diameter beam to locally heat and vaporize material. The process requires a vacuum system and machining chamber to generate and direct the electron beam without collisions. Key elements of an electron beam machining system include the electron beam gun to produce and focus the beam, a high voltage power supply, and computer controls to adjust process parameters like beam current, pulse duration, and beam positioning. Electron beam machining can drill small, high aspect ratio holes in both conductive and non-conductive materials without applying mechanical forces.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    574 views18 pages

    Electron Beam Machining

    Uploaded by

    Abhishek Kumar
    Electron beam machining uses a stream of electrons focused into a small diameter beam to locally heat and vaporize material. The process requires a vacuum system and machining chamber to generate and direct the electron beam without collisions. Key elements of an electron beam machining system include the electron beam gun to produce and focus the beam, a high voltage power supply, and computer controls to adjust process parameters like beam current, pulse duration, and beam positioning. Electron beam machining can drill small, high aspect ratio holes in both conductive and non-conductive materials without applying mechanical forces.

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    © All Rights Reserved
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    ELECTRON BEAM MACHINING

    (EBM)

    Sanjeev Sharma
    Professor
    CEC, Landran
    ELECTRON BEAM
    MACHINING
    • THERMAL TYPE
    ↓
    • CATHODE HEATED
    ↓
    • STREAM OF A LARGE NO. OF ELECTRONS AS A SMALL DIAMETER
    BEAM
    ↓
    • MOVES TOWARDS WORKPIECE
    ↓
    • BOMBARDMENT OF ELECTRONS IN A LOCALIZED AREA
    ↓
    • VERY HIGH TEMPERATURE
    ↓
    • MELTING AND VAPORIZA TION OF W/P MATLERIAL
    • KINTTIC ENERGY OF BEAM CONVERTS INTO HEAT
    ↓
    Contd…
     Can produce holes of different shapes

     Conducting as well as non-conducting materials

     Vacuum required in machining chamber

     Beam size < desired hole size

     Ejection of Molten Work piece Material


    – Vaporized backing material comes out at high pressure →
    expels molten work piece material

     Non-circular holes → move electron beam by computer


    control along hole perimeter
    ELEMENTS OF EBM SYSTEM
    ELEMENTS OF EBM SYSTEM
    • EBM gun
    • Power supply
    • Vacuum system & machining chamber
    ELECTRON BEAM MACHINING SYSTEM

    Schematic diagram of electron beam machining system


    EBM GUN
    • Operation in pulsed mode

    • Produces &focuses electron beam at predetermined location

    • Superheated cathode

    • Electrons cloud

    • Repelled from cathode & attracted by anode

    • Magnetic lens → converges beam

    • Stray electrons removed →reduced diameter of beam


    POWER SUPPLY
    • Generates voltage→150kV

    • Power → 12kW

    • Pulse Energy → 120 J/PULSE

    • Computer control of process variables

    • High power density


    ↓
    • Melting & vaporization

    • Material removal by vaporization


    VACUUM SYSTEM & MACHINING
    CHAMBER

    • Beam generation & travel → vacuum


    • No oxidation of filament
    • No collision of electrons& air molecules
    • Vacuum 10-4TO 10-5 TORR
    PROCESS PARAMETERS
    1. Beam current
    2. Pulse duration
    3. Lens current
    4. Beam deflecting signals
    PROCESS PARAMETERS
    1. BEAM CURRENT
    ↓
    100 µA to 1 A
    Governs energy/ pulse
    Higher value →higher MRR
    Contd…
    2. PULSE DURATION
    ↓
    50 µs tO 10ms
    ↓
    Long duration →wider & deeper hole
    ↓
    Affects HAZ & recast layer(0.025mm)
    Contd…
    3. LENS CURRENT
    ↓
    Determines working distance &beam size
    Contd…
    4. BEAM DEFLECTING SIGNALS
    ↓
    • Hole shape → position of focal point
    below top surface of w/p
    ↓
    • Shape other than circular → beam
    movements are programmed
    CHARACTERISTICS
     For conductive as well as non-conductive materials
     At entry side of beam→ a small sized burr
     W/p material properties do not affect performance
     Small diameter holes (0.1TO 1.4mm)
     Aspect Ratio = 15: 1
     No mechanical force → fragile, thin, low strength
    components →easily machined
     Off-axis holes easily made
     Residual thermal stresses → high temperature gradient
     Very high investment cost
     Skilled operator
     Machined edge quality → thermal properties of w/p
    material & pulse energy
     HAZ → Ф(pulse duration & hole diameter)
    APPLICATIONS
    • More popular → aerospace, insulation, food processing,
    chemical, clothing, etc

    • Holes in a w/p → complex-shaped, difficult-to-machine


    material, perforation, etc

     EXAMPLE: turbine engine combustor dome


     Fiber spinning head (thickness< 5 mm), much faster than
    EDM
     Holes in filters & screens → food industry
     Cooling holes in turbine blades
     Metering holes in injector nozzles
    Electron Beam Machining

    An electron beam in a very low-pressure atmosphere of helium

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