ELECTRO BEAM MACHINING

WORKING PRINCIPAL OF EBM

Cathode heated
Stream of large num of electrons as a
small diameter beam
Moves towards workpiece
Bombardment of electrons in a localized
area

Very high temperature

Melting and vaporization of w/p metal

INTRODUCTION

Electron-beam removal of materials is another

fast-growing thermal technique. Instead of
electrical sparks, this method uses a stream of
focused, high-velocity electrons from an electron
gun to melt and vaporize the work-piece material.

In EBM, electrons are accelerated to a velocity of

200,000 km/s or nearly three-fourths that of light.

INTRODUCTION
Can produce holes or different shapes.
Conducting and Non-conducting material both can
use.
Vacuum required in machine chamber.
Beam size< Desired hole size.
Ejection of molten w/p material.

Vaporized

backing material comes out at high pressure.

Non circular holes cut by move electron beam by

computer control along hole perimeter.

ELEMENTS OF EBM SYSTEM

EBM

Gun
Power Supply
Vacuum system
and
Machining
chamber

1. EBM GUN
Operation in pulsed mode.
Produces and focuses electron beam at
predetermine location.
Superheated cathode.
Electrons Cloud
Repelled from cathode and attracted by anode.
Magnetic Lens: Converges beam

2. POWER SUPPLY
Generates voltage up-to 150 Kv
Pulse energy 120 j/pulse
Computer control of process variable.
High power density.

Melting and vaporization

Material removed by vaporization.

3. VACUUM SYSTEM & MACHINING CHAMBER

Beam generation and travel in vacuum.
No oxidation of filament.
No collision of electrons and Air molecules.
Vacuum is 1 torr.

PROCESS PARAMETER OF EBM

Beam current
Pulse duration
Lens current
Beam deflecting signals.

1. BEAM CURRENT
1oo A To 1 A
Governs energy/ pulse.
Higher value
Higher MRR

2. PULSE DURATION
Pulse duration 50 s to 10 ms.
Long duration
Wider and deeper hole.
Affects HAZ and Recast layer ( < 0.025 mm).

3. LENS CURRENT

Determines working distance and beam size.

4. BEAM DEFLECTION SIGNALS

Holes 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 not non conductive materials.

w/p materials properties do not affect performance.
Small diameter holes 0.1 to 1.4 mm.
Aspect ratio 15: 1.
No mechanical force: fragile thin, low strength component can
be easily machined.
Off axis holes easily made.
Residual thermal stresses due to high temperature gradient.
Very high investment cost.
Skilled operator.
Machined edge quality is depends on thermal properties of
w/p material and pulse energy.
HAZ is depends on pulse duration and hole diameter.

APPLICATIONS
More popular: Aerospace, Insulation, Food
Processing. Chemical clothing, etc.
Hundreds of thousands of hole in w/p.
Difficult to machine material

Turbine

engine combustor dome.

Fiber spinning head, much faster than EDM.
Cooling. holes in turbine blades.
Metering holes in injector nozzles.