Electron Beam Machining

Electron Beam Machining is process in which high velocity electrons are concentrated in a narrow
beam and then directed towards the workpiece for machining. When this high velocity electron strikes
the workpiece, it melts and vaporizes the material from the workpiece.

Working Principle
In an electron beam machining, the electrons strike the workpiece with a high velocity. As the electron
strikes the workpiece, the kinetic energy of the electron changes into heat energy. The heat energy so
produced is used to melt and vaporize the materials from the w/p. The whole process takes place in
vacuum. Vacuum environment is used to prevent the contamination and avoid collision of electrons
with air molecules. If the electrons collide with the air molecules, it will lost its Kinetic energy.

Diagram
 1. Cathode
The cathode is negatively charged and it is used to produce Electrons.

2. Annular Bias Grid

It is present next to the cathode. Annular bias grid is a circular shaped bias grid and prevents the
diversion of electrons produced by the cathode. It works as a switch and makes the electron gun to
operate in pulse mode.

3. Anode
It is placed after the annular bias grid. It is positively charged. Annular anode attracts the beam of
electron towards it and gradually the velocity of the electron increases. As the electron beam leave
the anode section, its velocity becomes half of the velocity of light.

4. Magnetic Lenses
The magnetic lenses reduce the divergence of electron beam and shape them. It allows only
convergent electrons to pass and captures the low energy divergent electrons from fringes. It
improves the quality of the beam.

5. Electromagnetic Lens
It helps the Electron beam to focus on the desired spot.

6. Deflector Coils
The deflector coil carefully guides the high velocity electron beam to a desired location on
the workpiece and improves the shape of the holes.

Working of Electron Beam Machining

▪ In EBM, first the electron is generated by the cathode and an annular biased grid does not allows
the electron to diverge.
▪ From the annular bias grid, the electron produced by the cathode is attracted towards the anode
and gradually its velocity increases. As the electron beam leaves the anode section, its velocity
reaches to half of the velocity of the light.
▪ After that, it passes to the series of magnetic lenses. The magnetic lenses allows only convergent
beam to pass through it and captures the divergent beam from the fringes. And then a high
quality electron beam is made to pass through the electromagnetic lens and deflector coils.
▪ The electromagnetic lens focuses the electron beam to the desired spot on the workpiece. The
deflector carefully guides the beam to the desired locations and improves the shape hole.
▪ The whole process is done in vacuum to avoid any speed rection of electron (as it collides with
air it reduces its kinetic velocity of electrons)

Characteristics
(i) The Electron Beam machine is operated in pulse mode and this is achieved by the biasing annular
biased grid.
(ii) The beam current can be as low as 200 μamp to 1 amp.
(iii) The pulse duration achieved in the EBM machine is 50 μs to 15 ms.
(iv) The energy possessed by the pulse is 100 j/pulse.
(v) It utilizes voltage in the range of 150 kV to 200 kV. And this voltage is used to accelerate
Electrons to about 200,000km/s.
Advantages
▪ It can produce bolts of small sizes.
▪ High accuracy and better surface finish.
▪ Almost all types of materials can be machined.
▪ Highly reactive metals such as Al and Mg can be machined easily.
▪ As it does not apply any mechanical cutting forces on the workpiece, so cost of work holding
and fixtures is reduced
Disadvantages
▪ High equipment cost.
▪ Low metal removal rate.
▪ High skilled operator is required.
▪ High power consumption.
▪ Not applicable to produce perfectly cylindrical deep holes.
Application
Electron Beam Machining is used to produce smaller size holes in various industries like automobile,
aerospace, marine etc.
 Plasma Arc machining
Plasma-arc machining (PAM) employs a high-velocity jet of high-temperature gas to melt and
displace material in its path. Called PAM, this is a method of cutting metal with a plasma-arc, or
tungsten inert-gas-arc, torch. The torch produces a high-velocity jet of high-temperature ionized
gas called plasma that cuts by melting and removing material from the workpiece. Temperatures
in the plasma zone range from 20,000° to 50,000° F (11,000° to 28,000° C)

This article consists of the Plasma arc machining working principle, plasma arc machining
diagram, process, advantages and Disadvantages of plasma arc machining, application of plasma
arc machining.

What is Plasma
Solids, liquids, and gases are the three familiar states of matter. In general when solid is heated, it
turns to liquids and the liquids eventually become gases. When a gas is heated to sufficiently high
temperature, the atoms (molecules) are split into free electrons and ions. The dynamical properties
of this gas of free electrons and ions are sufficiently different from the normal unionized gas. So,
it can be considered a fourth state of matter, and is given a new name, PLASMA’. In other words,
when the following gas is heated to a sufficiently high temperature of the order of 11,000°C to
28,000°C, it becomes partially ionized and it is known as ‘PLASMA’. This is a mixture of free
electrons, positively charged ions, and neutral atoms.

This plasma is used for the metal removal process. The plasma arc machining process is used for
cutting alloy steels, stainless steel, cast iron, copper, nickel, titanium, and aluminum, etc.

Working Principle of PAM

In the plasma arc machining process, the material is removed by directing a high-velocity jet of
high temperature (11000°C to 28,000°C) ionized gas on the workpiece. This high-temperature
plasma jet melts the material of the workpiece.
Process Details of PAM
Details of PAM are described below.

• Plasma Gun

Gases are used to create plasma-like, nitrogen, argon, hydrogen, or a mixture of these gases.
The plasma gun consists of a tungsten electrode fitted in the chamber. The electrode is given
negative polarity and the nozzle of the gun is given positive polarity. The supply of gases is
maintained into the gun. A strong arc is established between the two terminals anode and
cathode. There is a collision between molecules of gas and electrons of the established arc. As
a result of this collision, gas molecules get ionized and heat is evolved. This hot and ionized
gas called plasma is directed to the workpiece with high velocity. The established arc is
controlled by the supply rate of gases.

• Power Supply and Terminals

Power supply (DC) is used to develop two terminals in the plasma gun. A tungsten electrode
is inserted to the gun and made cathode and nozzle of the gun is made anode. Heavy potential
difference is applied across the electrodes to develop a plasma state of gases.

• Cooling Mechanism
As we know that hot gases continuously come out of nozzle so there are chances of its
overheating. A water jacket is used to surround the nozzle to avoid its overheating.

• Tooling
There is no direct visible tool used in PAM. Focused spray of ho0t, plasma state gases works
as a cutting tool.
• Workpiece

The workpiece of different materials can be processed by the PAM process. These materials are
aluminum, magnesium, stainless steel, and carbon and alloy steels. All those material which can
be processed by LBM can also be processed by the PAM process

Construction Of Plasma arc Machining :

• The schematic arrangement of plasma arc machining is shown in Fig.
• The plasma arc cutting torch carries a tungsten electrode fitted in a small chamber.
• This electrode is connected to the negative terminal of a DC power supply. So it acts as a cathode.
• The positive terminal of a D.C power supply is connected to the nozzle formed near the bottom of
the chamber. So, nozzle acts as an anode.
• A small passage is provided on one side of the torch for supplying gas into the chamber.
• Since there is a water circulation around the torch, the electrode and the nozzle remains water-
cooled.
Working of PAM :

• When a D.C power is given to the circuit, a strong arc is produced between the electrode
(cathode) and the nozzle (anode).
• A gas usually hydrogen (H2) or Nitrogen (N2) is passed into the chamber.
• This gas is heated to a sufficiently high temperature of the order of 11,000°C to 28,000°C
by using an electric arc produced between the electrode and the nozzle.
• In this high temperature, the gases are ionized and a large amount of thermal energy is
liberated.
• This high velocity and high-temperature ionized gas (plasma) is directed on the workpiece
surface through the nozzle.
• This plasma jet melts the metal of the workpiece and the high-velocity gas stream
effectively blows the molten metal away.
• The heating of workpiece material is not due to any chemical reaction, but due. to the
continuous attack of plasma on the workpiece material. So, it can be safely used for
machining of any metal including those which can be subjected to the chemical reaction.

ADVANTAGES OF PAM

1. It can be used to cut any metal.

2. The cutting rate is high.
3. As compared to the ordinary flame cutting process, it can cut plain carbon steel four times faster.
4. It is used for rough turning of very difficult materials.
5. Due to the high speed of cutting, the deformation of sheet metal is reduced while the width of
the cut is minimum and the surface quality is high.
DISADVANTAGES OF PAM
1. It produces a tapered surface.
2. The protection of noise is necessary.
3. The equipment cost is high.
4. Protection of eyes is necessary for the operator and persons working in nearby areas.
5. Oxidation and scale formation takes place. So, it requires shielding.
6. The work surface may undergo metallurgical changes.

APPLICATIONS
1. It is used for cutting alloy steels, stainless steel, cast iron, copper, nickel, titanium,
aluminum, and alloy of copper and nickel, etc.
2. It is used for profile cutting.
3. It is successfully used for turning and milling of hard to machine materials.
4. It can be used for stack cutting, shape cutting, piercing, and underwater cutting.
5. Uniform thin film spraying of refractory materials on different metals, plastics, ceramics
are also done by plasma arcs.