Electron Beam Machining / Definition, parts, working, advantages, disadvantages of Electron Beam Machining

Introduction:

This machining process works on the basic principle of converting the kinetic energy of electrons into heat energy.  

When a high-speed electron strikes a piece of a workpiece, they convert their kinetic energy into heat energy.   

This heat energy evaporates the material on the surface of the workpiece. 

This process is done in a vacuum otherwise the electron collides with the air particle and loses its energy before hitting the material. It is mostly used for drilling holes in any shape.

See in figure electron beam machining process and their working procedure described below in detail.

Working Procedure of Electron Beam Machining:

1. Firstly the electron gun produces electron particles with high velocity.  
2. These electron particles move towards the anode. The anode is placed after the cathode tube. 
3. Now it highly intense electron beam passes through magnetic lenses. There is a chain of lenses that only takes care of the converging electron that passes through it. It absorbs all divergent electrons and low energy electrons.  It provides a high-quality electron beam.
4. This electron beam now passes through the electromagnetic lens and deflecting coil which focuses the electron beam at one spot.  
5. A highly intense electron beam strikes the piece of the workpiece where the kinetic energy of the electrons is converted into thermal energy.    
6. Due to this high temperature generated by the conversion of kinetic energy into heat energy, the substance melts and vaporizes, due to which the material begins to be removed (cut).  
7. This whole process takes place in a vacuum chamber otherwise these electrons collide with the air particle between the path and lose their kinetic energy.

Application of Electron Beam Machining:

1. It is used to produce holes of very small sizes from 100 micrometers to 2 millimeters. 
2. It is used for making holes in diesel injection nozzles. 
3. Used in the aerospace industries for the production of turbine blades for supersonic engines and in nuclear reactors.

Advantages of Electron Beam Machining:

1. It can be used to produce the very small size of holes in any shape.  
2. It can machine any material irrespective of its hardness and other mechanical properties. 
3. It provides a good surface. 
4. Highly reactive materials can be easily machined because machining is done under a vacuum. 

Disadvantages of Electron Beam Machining :

1. Capital cost is high. 
2. Require high skill operator. 
3. The rate of material removal is low.  
4. Require regular maintenance. 
5. Producing the perfect vacuum is difficult.

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