Electron Beam Machining (EBM)

by ME Mechanical TeamMar 17

Electron Beam Machining (EBM) is a thermal process. Here a steam of high

speed electrons impinges on the work surface so that the kinetic energy of
electrons is transferred to work producing intense heating.

Depending upon the intensity of heating the workpiece can melt and vaporize.

The process of heating by electron beam is used for annealing, welding or metal
removal.

During EBM process very high velocities can be obtained by using enough
voltage of 1,50,000 V can produce velocity of 228,478 km/sec and it is focused
on 10 200 M diameter. Power density can go up to 6500 billion W/[Link].
Such a power density can vaporize any substance immediately.

Complex contours can be easily machined by maneuvering the electron beam

using magnetic deflection coils.

To avoid a collision of the accelerating electrons with the air molecules, the
process has to be conducted in vacuum. So EBM is not suitable for large work
pieces.

Process is accomplished with vacuum so no possibility of contamination.

No effects on work piece because about 25-50 m away from machining spot
remains at room temperature and so no effects of high temperature on work.

Schematic diagram of Electron Beam Machining process

MRR in EBM:
Q = area of slot or hole speed of cutting = AV
Where power for Q MRR is P = C.Q
Where,
C = Specific power consumption
Thermal velocity acquired by an electron of the work material due to electron beam is

Where, KB = Boltzmann constant

m = mass of one atom of work.
T = rise in temperature
Advantages:

Very small size holes can be produced.

Surface finish produced is good.

Highly reactive metals like Al and Mg can be machined very easily.

Limitations:

Material removal rate is very low compared to other unconventional machining

processes.

Maintaining perfect vacuum is very difficult.

The machining process cant be seen by operator.

Workpiece material should be electrically conducting.

Applications:

Used for producing very small size holes like holes in diesel injection nozzles, Air
brakes etc.

Used only for circular holes.

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Electron Beam Machining

Electron Beam Machining

Electron beam machining is a thermal process used for the metal removal during the
machining process. In the electrical beam machining, electrical energy is used to
generate the electrons with high energy.

Process of Electron Beam Machining Process:

In the electron beam gun the electric beam is generated. Electron beam
consists of a small spot size, from which it provides the high velocity
electrons. The electron beam machining process is carried out in the
vacuum. This is due to the electrons present in the process react with the air
molecules so they lose the energy and ability of cutting. The work piece
material must be placed under the electron beam, and where the equipment
is placed under the vacuum. With the spot size of 10 to 100 , the high
energy absorbed electron beam is ready to show impact on the work piece
material. The high velocity electron consists of kinetic energy, the energy is
converted into the heat energy, where the electrons strikes the work
material. Because of the high energy present in the electrons it starts to
melting and vaporization of the work piece material. The process is done
from top to the bottom of the work piece material. In the electrical beam
machining the gun is used in the pulsed mode. By using the single pulse
holes, and is drilled on the thin sheets. Multiple passes are required for the
thicker plates.
Equipment used in the Electron Beam Machining:

Cathode, Bias grid, anode, electromagnetic lens, electromagnetic coils,

deflector coils, telescope, vacuum gauge, throttle valve, diffusion
pump.
The electron beam machine consists of an electron beam gun used to
produce free electrons at the cathode. The high velocity particles are
moving through the small spot size. The cathode (tool) is made of
tantalum or tungsten material. The cathode filaments are heated to a
temperature of 2500to 3000and the heating leads to thermo ionic
emission of electrons. The magnitude varies from the 25 mA to 100
mA. The solidities lies between 5 Ac to 15 Ac .The emission current is
influenced by the voltage that is nearly 150kV, and the current is
applied between the anode and cathode to release the electrons in the
direction of work piece.
Bias grid: It is also known as grid cup. The grid cup is a negative that
is subjected with respect to the filament. So, the electrons generated
with the help of the cathode will directly flow towards the anode.
During the flow of the electrodes no diversions are seen. The anode
attracts the electrons and gets accelerated; the electrons will gain a
high velocity.
The cathode controls the flow of the electrons, and the grid cup used to
operate the gun in pulsed mode only.
After the anode the electron beam passing through the magnetic lens
and the apertures are connected in series. The magnetic lens is used
to shape the electron beam and reduce the diversion factor.
The apertures allow the convergent electrons to permit and caught the
low energy divergent electrons from the fringes.

Finally the electron beam passes through the electromagnetic lens and
deflection coil. Then the deflection coil sends the electron beam
through the hole, to improve the shape to machine a hole.
The vacuum is created between the work piece and the electron beam
gun, and there is a series of rotating disc with slots.
The disc allows the electron beam to pass over the material for
machining, and it prevents from the fumes and vapors generated
during the machining.
Work piece is placed on the CNC bench. Then holes of any shape are
made on the work piece material. In the gun beam flection and CNC
control are used to shape.
Vacuum is maintained in gun, and the vacuum ranges from Suitable
vacuum is maintained because the electron as it does not lose their
energy, and where the life of the cathode is obtained. By using the
diffusion pump and rotary pump the vacuum is maintained.
Diffusion pump should act as an oil heater. If the oil is heated then the
oil vapor rushes upwards. The nozzle changes the direction of the oil
vapor and starts moving in the downward direction at high velocity.
The oil vapors are reduces in the diffusion pump; this is because of the
presence of the cooling water cover.
Parameters in the Electron discharge machining:
We already know that the electron gun is works within the pulse mode.
The bias grid is located after the cathode. Then pulse is given to the
grid cup, where the pulse duration ranges from 50to 15 ms.
Beam current is related to the electrons that are emitted from the
cathode or available in the beam. Beam current is ranges from the
200micro amps to 1 amp. If the beam current increases,
simultaneously there is also an increase in the energy per pulse. High
pulse energy is used to machine thicker plates and make the holes
larger.
The power and energy density is ruled by the energy per pulse and the
nozzle spot size. With the help of the electromagnetic lens the spot
size is controlled. For lower spot size they require a high energy
density. The metal removal must be high; this is when compared to the
holes size where the hole must be similar.
The plane of focusing must be above or below the surface of the work
piece material.
Capability of Electron Beam machining process
Electrical beam machining makes a hole ranges from 100 to 2 mm.
The depth of cut must be 15 mm with a length to diameter ratio of
nearly 10.
Holes can be elongated along with the barrel shape or depth.
Reverse tapper can also be performed below the surface of the work
piece material.

In the electron discharge machining Cut formation is not observed

With the help of the electron discharge machining we can machine the
wide range of materials like stainless steel, aluminum, steel, plastics,
ceramics etc.
In EBM the heat affected zone is narrow; this is because of the short
pulse occurrence. The heat affected zone is nearly 20 to 30
Compares to the steels aluminum and titanium is freely machined.
Based upon the type of the material, power density, depth of cut holes
diameter, which are the reasons for the number of holes drilled per
second on the material.
The EBM does not apply any cutting forces on the material.
During the process very simple investment is required for work
EBM process allows machining of brittle and fragile materials.
Holes are drilled at an angle of 20 to 30
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:
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.
Applications of EBM:
With the help of the different pressure, holes are drilled in the air craft engine, nuclear
reactor etc.
We can see small cross sectional area in the wire drawing die-machines.
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Electron beam machining

From Wikipedia, the free encyclopedia

Electron-beam machining (EBM) is a process where high-velocity 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.

Process[edit]
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. 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 [Link] electron beam is generated by the potential difference between the cathode and
anode .cathode is negatively charged and anode is positive charged.

Equipment[edit]
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.

Considerations[edit]
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 use EBM equipment.

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