Photochemical Machining (Pcm)
Indian Institute of Technology, Kanpur
PHOTOCHEMICAL MACHINING (PCM)
ME662 Advanced Machining Processes
Tarun Mankad Y4456
October 05, 2007
CONTENTS
INTRODUCTION 5
PROCESS OUTLINE 7
PROCESS COMPONENTS 8
PCM PRODUCTS 21
COST DRIVERS 27
ADVANTAGES OF PCM 28
CONCLUSION 29
REFERENCES 31
LIST OF ILLUSTRATIONS
Illustration 1: the current PCM process 7
Illustration 2: process flow-chart 9
Illustration 3: etch profile development with time 14
Illustration 4: existing Regeneration Systems 19
Illustration 5: problems with different regeneration methods 20
Illustration 6: disposal of waste elements 20
Illustration 7: idealized PCM process of the future 30
LIST OF TABLES
Table 1: different etching technologies and products 8
Table 2: PCM etchants 8
Table 3: cost drivers 21
INTRODUCTION
Definition:
Photo chemical machining is an engineering production technique for the manufacture of burr free and stress free flat metal components by selective chemical etching through a photographically produced mask.
Overview:
Photochemical machining (PCM) is one of the least well-known non-conventional machining processes. The technique is relatively modern and became established as a manufacturing process about fifty years ago.
PCM is also known as photoetching, photochemical milling, photomilling, photofabrication, photochemical etching and (in the USA) chemical blanking. The processing technology has been kept a closely-guarded secret within a small number of industrial companies but despite this, the sales of parts made by PCM at the end of the twentieth century was approximately US$ 6 billion. [1]
The PCM industry plays a valuable worldwide role in the production of metal precision parts and decorative items. Parts produced by PCM are typically thin, flat, and complex. These parts have applications in electronics, mechanical engineering, and the aerospace industry. The increasing
PHOTOCHEMICAL MACHINING (PCM)
ME662 Advanced Machining Processes
Tarun Mankad Y4456
October 05, 2007
CONTENTS
INTRODUCTION 5
PROCESS OUTLINE 7
PROCESS COMPONENTS 8
PCM PRODUCTS 21
COST DRIVERS 27
ADVANTAGES OF PCM 28
CONCLUSION 29
REFERENCES 31
LIST OF ILLUSTRATIONS
Illustration 1: the current PCM process 7
Illustration 2: process flow-chart 9
Illustration 3: etch profile development with time 14
Illustration 4: existing Regeneration Systems 19
Illustration 5: problems with different regeneration methods 20
Illustration 6: disposal of waste elements 20
Illustration 7: idealized PCM process of the future 30
LIST OF TABLES
Table 1: different etching technologies and products 8
Table 2: PCM etchants 8
Table 3: cost drivers 21
INTRODUCTION
Definition:
Photo chemical machining is an engineering production technique for the manufacture of burr free and stress free flat metal components by selective chemical etching through a photographically produced mask.
Overview:
Photochemical machining (PCM) is one of the least well-known non-conventional machining processes. The technique is relatively modern and became established as a manufacturing process about fifty years ago.
PCM is also known as photoetching, photochemical milling, photomilling, photofabrication, photochemical etching and (in the USA) chemical blanking. The processing technology has been kept a closely-guarded secret within a small number of industrial companies but despite this, the sales of parts made by PCM at the end of the twentieth century was approximately US$ 6 billion. [1]
The PCM industry plays a valuable worldwide role in the production of metal precision parts and decorative items. Parts produced by PCM are typically thin, flat, and complex. These parts have applications in electronics, mechanical engineering, and the aerospace industry. The increasing
References: [1] Allen, D.M., 2004, Photochemical Machining: from ‘manufacturing’s best kept secret’ to a $6 billion per annum, rapid manufacturing process, Annals of the CIRP, 53/2. [2] Roy R., Allen D.M. and Zamora O., 2004, Cost of photochemical machining, Journal of Materials Processing Technology, 149, 460-465. [3] Allen, D.M. and Ler, L.T., 1999, Increasing utilization efficiency of ferric chloride etchant in industrial photochemical machining, J. Environmental Monitoring, 1, 103-108. [4] Allen, D.M. and Almond H.J.A., 2004, Characterization of aqueous ferric chloride etchants used in industrial photochemical machining, Journal of Materials Processing Technology, 149, 238-245. [5] Allen, D.M., 1993, Progress towards clean technology for photochemical machining, Annals of the CIRP, 42/1,197-200. [7] Allen, D.M., 1987, Three-dimensional photochemical machining, Annals of the CIRP, 36/1, 91-94. [1] Allen, D.M., 2004, Photochemical Machining: from ‘manufacturing’s best kept secret’ to a $6 billion per annum, rapid manufacturing process, Annals of the CIRP, 53/2. [2] Roy R., Allen D.M. and Zamora O., 2004, Cost of photochemical machining, Journal of Materials Processing Technology, 149, 460-465. [3] Allen, D.M. and Ler, L.T., 1999, Increasing utilization efficiency of ferric chloride etchant in industrial photochemical machining, J. Environmental Monitoring, 1, 103-108. [4] Allen, D.M. and Almond H.J.A., 2004, Characterization of aqueous ferric chloride etchants used in industrial photochemical machining, Journal of Materials Processing Technology, 149, 238-245. [5] Allen, D.M., 1993, Progress towards clean technology for photochemical machining, Annals of the CIRP, 42/1,197-200. [6] Allen, D.M., 1987, Three-dimensional photochemical machining, Annals of the CIRP, 36/1, 91-94.