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Group H Assignment 1

Assignment 2

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10 views

Group H Assignment 1

Assignment 2

Uploaded by

yahayasaka10
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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COURSE TITLE: MACHINE TOOLS

COURSE CODE: MEC3205


DATE SUBMITTED: 12/FEB/2024

ASSIGNMENT ON CHEMICAL MACHININING PROCESS


GROUP MEMBERS

HAYATU ABDULSALAM YAHAYA ENG/21/MEC/00642

MURTALA ABDULLAHI ENG/19/MEC/00284

UMEH SAINT ENG/19/MEC/00301

YAHAYA SAKA ENG/21/MEC/00641

ALIYU SALEH MUHAMMAD ENG/21/MEC/00647

MUBARAK HARUNA ENG/21/MEC/00648

ABDULAZEEZ ABIODUN ABDULWASIU ENG/17/MEC/00407


CHEMICAL MACHINING PROCESS
Chemical Machining Process is the material removal process for the production of desired
shapes through selective or overall of material by controlled chemical attack with acid or alkalis.
This is one of the oldest nontraditional machining process and also has oldest some drawbacks.
The main issue faced by chemical machining process is the reduced material removal rate when
compared to other nontraditional machining techniques. Accuracy of machine should also paid
attention. Apart from this, since we are using chemical etchant for the process, it also has some
environmental issues. The machining quality of chemical machining is comparatively less. So it
is necessary to think of an idea to improve the quality.

This process is well known as nontraditional machining process and is controlled by


chemical dissolution of the machines work piece material by contact with a strong chemical
reagent. It is also known as a chemical etching. Most of all the material from metal to ceramics
can be chemically machined. Chemical machining process is employed where metal removal is
difficult. It is a controlled dissolution of the work material by means of contact with a strong acidic
or alkaline chemical reagent. The major characteristics of chemical machining are material
removal rate, accuracy and surface finish.

WORKING PRINCIPLE OF CHEMICAL MACHINING

The process of chemical machining is based on chemical etching the part of the work piece
metal material is to be removed. The work piece is brought in contact with a strong corrosive
chemical called etchant. The Etchant react with the work piece in the material to be cut and causes
the solid material to be removed. Thus the metal is removed by the chemical attack of the etchant.

The portion of the work material where material is not be removed is protected from chemical
attack by means special coating called Maskants. So by this chemical machining process from all
metal to ceramic substance can be machined with chemical machining process. This process of
chemical reaction between the material of the work piece and some chemical reagent use to
produce a reaction between then so that it can be removed easily. The surface of the work piece
is etched away, exposing the lower layers, and the process is continued until the desired amount
of material is removed.
Brief illustration of the chemical machining process.

NEED FOR CHEMICAL MACHINING

Hard and difficult metals cannot be easily machined by conventional machining methods.
Further thin work piece with complex configuration or delicate parts fail to withstand the forces
of cutting tool. Although some nontraditional process can be used in such conditions, they are not
economical due to high capital and tooling cost involved. These disadvantages are overcome with
the use of chemical machining process.

TYPES OF CHEMICAL MACHINING PROCESS

There are two type of chemical machining:

a. Chemical blanking method


b. Chemical milling or contour machining method

PROCEDURE FOR CHEMICAL MACHINING

Work piece pre cleaning process: The surface of work piece metal is cleaned thoroughly,
degreased and pickled by acid or alkalis. Pre cleaning is the most important method to remove oil,
grease, dirt, rust or any foreign substance from the work surface to produce a good adhesion of
masking material.

Masking and scribing mask: Masking involves covering the portion of the work piece metal
where material is not to be removed by the chemical action. Masking with adhesive types of paints
is a common practice although rubber (elastomers) and plastic are also used. Since it is difficult
to apply maskant on small surface, the maskant is initially applied on a large surface.
Etching: The unmasked of the work piece is machined chemically with selected etchant. Etching
is carried out by immersing the work material in a tank of agitated etchant. The process is carried
out at high temperature depending on the etched material. Temperature control and agitation
during chemical machining. Erosion of the work materials takes place from the exposed surface.

Damasking: When etching is completed the mask is removed either through mechanical or
chemical means. Any etchant on the work material is also removed by cold water to clean.

CHARACTERISTICS OF CHEMICAL MACHINING

i. Metal removal rate


ii. Accuracy
iii. Surface finishing

Maskants

Masking material is known as maskant which is used to protect work piece surface from chemical
etchant. In another word, maskants protect the portion of work piece metal where material is not
to be removed by chemical action of the etchant. Polymers or rubber based material are generally
used as a maskant material. Various maskant application methods can be used such as dip, brush,
spray, as well as adhesive tapes.

Factors to be considered when selecting maskant for machining

 Adhere well to the work piece


 Be removed easily after etching
 Be inexpensive after etching
 Be able to withstand the heat generation by etching
 Availability and low cost

Etchants

Etchant are acid or alkaline solutions maintained within a controlled range of chemical
composition and temperature. The work piece material to be removed is sprayed or immersed in
a suitable etchant. The type of etchant to be selected for machining is based on following factor:
1. Type of work piece metal that is being etched
2. Rate of metal removal
3. Surface finish required
4. Type of maskant used
5. Depth of etched
6. Un harmful or nontoxic to human operator

ETCHANT CHARACTERISTICS

Work Material Etchant Etchant Temperature

Aluminum and alloys Ferric chloride 49


Copper and alloys Cupric chloride 49
Steel Ferric chloride 54
Nickel Ferric chloride 49
Magnesium Nitric acid 49

REFERENCES:

1. https://irjiet.com/common_src/article_file/1574155468_d29ca360e5_3_irji-et.pdf
2. https://pesjournal.net/journal/v4-n1/5.pdf
3. https://testbook.com/amp/mechanical-engineering/chemical-machining
4. https://theengineeringspost.com/chemical-machining/
5. https://mechanicaljungle.com/working-of-chemical-machining/

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