ChM is a process of controlled dissolution w/p material by contact with strong

reagent and protecting the part by maskants from which material is not to be
removed.
Used for material having high strength to weight ratio
ChM consists of following steps:
Preparing and precleaning the w/p surface
Masking using readily strippable mask, which is chemically impregnable and
adherent enough to stand chemical abrasion during etching
Masking material depends on
Size of w/p; number of parts to be made; desired resolution of details
Scribing of mask to expose areas that receive ChM
w/p is then etched and rinsed in etchant or reagent with temperature ranging from
37-85
o
C

Depth of cut is controlled by time of immersion

Chemical machining set-up
Machining process proceeds both inwardly from mask opening and laterally beneath mask,
thus creating etch factor.
Etch factor is ratio of undercut d to depth of etch T.

Radius of fillet is approx. equal to depth of cut.












Maskants should posses following properties
Be tough enough to withstand handling
Adhere well to w/p
Scribe easily
Be inert to chemical reagent


Be able to withstand heat generated by etching
Removed easily and inexpensively after etching
Maskants are of three types
Cut and peel
Photographic
Screen resists

Etchant
Basic function of etchant is to convert a material in to a metallic salt that can be dissolved in
etchant, thus removed from work surface.
Etchant selection is based on
Material to be etched
Type of maskant or resist used
Depth of etch
Surface finish require d
Potential damage to metallurgical properties of w/p
Rate of material removal
Economics


Process parameters
ChM process parameters including reagent solution type, concentration, properties,
mixing, operating temperature, and circulation will directly impact on w/p regarding
following
Etch factor
Etching and machining rate
Production tolerance
Surface finish

The MRR depends on the chemical and metallurgical uniformity of w/p and uniformity
of solution temperature with casting having largest grain size, show roughest SF
together with lowest machining rate.
Rolled metal sheets have highest machining rate accompanied by best surface quality
Etching rates are high for hard metals and low for softer ones
Generally, high etch rates is accompanied by low surface roughness, hence narrow
machining tolerances
Advantages
Several parts can be machined simultaneously
Machined or extruded parts may be reduced on selected areas or all over by ChM to provide
web sections thinner than those obtainable by conventional machining
Casting are designed uniformly oversized, heat treated with little or no warpage, and then
chemically machined to achieve final desired dimensions
Extrusion, forging, casting, formed sections and deep drawn parts can be lightened
considerably by ChM

Disadvantages
Handling and disposal of chemicals can be trouble some
Surface imperfection are produced
Metallurgical homogeneous surfaces are required
Deep narrow cuts difficult to produce
Steep tapers are not practical
Welded areas frequently etch at rates that differ from base metal.