ELECTRON BEAM MACHINING (EBM)

Basic Introduction
EBM is a process where a narrow beam of high-velocity electrons are directed toward the
workpiece, creating heat & vaporizing the material.
● Energy domain: Thermal
● Beam current: No of electrons crossing any section per second.
● Vacuum is compulsory to reduce contamination by electron collisions with air molecules.

Working principle
A pulsating stream of high-speed electrons carry immense kinetic energy.
● When they impinge on workpiece generates very high temperatures.
○ Kinetic energy converts to thermal energy.
● Due to this the metal melts / vapourises & results in metal cutting / machining.
● Vacuum is required to avoid contamination of electrons by collision with air molecules.

Equipment
● Electron gun: It generates high velocity concentrated electron beam. It consists of
○ Cathode: Negatively charged electrode that emits electrons.
■ is made of tantalum or tungsten material
○ Bias grid: It is also known as grid cup.
■ It is a negatively charged with respect to the filament.
○ Anode: Positive electrode in the shape of a ring that converges the beam.
● Electromagnetic lens: Consists of Electromagnetic coils that generates electric field to
deflect / focus electron beam.
● telescope, vacuum gauge, throttle valve, diffusion pump.
● EBM equipment in construction is similar to electron beam welding machines.

Process Description
● Electron gun emits a pulsed beam of electrons which are diverging initially.
○ DC voltage of about 150kV applied.
○ The cathode filaments get heated to 2500°C to 3000°C.
○ It leads to thermo-ionic emission of electrons.
○ The cathode controls the flow of the electrons.
○ The solidities lies between 5 Ac to 15 Ac.
● Bias grid: The electrons emitted from cathode will directly flow towards the anode.
○ During the flow of the electrodes no diversions are seen.
○ The grid cup is used to operate the gun in pulsed mode only.
● The anode attracts the electrons & accelerates them to a high velocity.
● The beams pass through electromagnetic lens & get focussed suitably.
○ Computers / numerical control is employed for precise control.
○ Spot size is controlled by the degree of focusing of the electromagnetic lenses.
○ the apertures are connected in series.
○ It shapes the electron beam & reduce the diversion factor.
○ The apertures allow the convergent electrons & stop the low energy divergent
electrons from the fringes.
● Vacuum is maintained throughout the path of electron beam.
○ A diffusion pump & rotary pump are used to maintain vacuum.
■ 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 & 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.
○ Vacuum prevents collisions of electrons with gas molecules, which would scatter or
diffuse the beam
○ It also protects the workpiece from oxidation and other atmospheric contamination.
● Lead shielding is required to protect the operator from X-ray radiation produced by the
electron beam.
● there is a series of rotating disc with slots.
○ The disc allows the electron beam to pass over the material for machining,
○ it also prevents the fumes & vapors generated during the machining.
● Work piece is placed on the bench that is CNC controlled for holes or required shape.

Process Variations

Process Parameters
● Voltages range: 150 to 200 kV
● Cathode current: 25 mA to 100 mA.
● Power range: 0.5kW to 60 kW
○ P = CQ
■ P - Power
■ C - specific power consumption.
■ Q - Material removal rate
● Beam intensity: 1.55x10​5​ to 1.55x10​9​ W/cm​ 2
● Beam current: Range is 0.1 mA to 1 mA.
○ Increasing the beam current directly increases the energy per pulse.
● Velocity of electrons: about 200,000 km/s (2/3​rd​ of Light!)
● Pulse duration: Range is from 50 µs to 15 ms.
○ Similarly increase in pulse duration also enhances energy per pulse.
● Power density: 6500 x10​9​ W/mm​2​.
● Formula for thermal velocity of electrons in the beam:

○
■ Where, K​B​= Boltzmann constant
■ M = mass of one atom of work.
■ T = rise in temperature
● 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.
●

Performance Characteristics
● Focus diameter: 10 – 200 µM diameter.
● Material Removal Rate - MRR = A.V
○ A - area of slot hole
○ V - cutting velocity
● Kerf width (Narrowest cut): 0.03 mm
● Max depth of cut: 15 mm
● penetration rates: up to 0.25 mm/s
● Length to diameter ratio: 10.
○ i.e. Hole depth can be 10 times its diameter.
● In the electron discharge machining Cut formation is not observed
● Materials: stainless steel, aluminum, steel, plastics, ceramics etc.
○ Allows machining of brittle & fragile materials.
● Heat affected zone: 25-50µm.
● Compared to the steels, aluminum & titanium is freely machined.
● Holes can be drilled at an angle of 20 to 30
Advantages
● Very small size holes (0.002 inches) can be drilled with high accuracy.
● Compared to other thermal cutting processes, EBM gives
○ better surface finish
○ narrower kerf width
● Highly reactive metals like Al & Mg can be machined very easily.
● Pulse energy can be adjusted for thicker plates & larger holes.
● There is no direct contact hence all tool related problems do not exist.
○ No cutting forces.
○ No tool replacement required.
● No distortions.
● High accuracy & repeatability.
● Complex contours can be easily obtained deflecting electron beam using electromagnets.
● Small spot size (25-50µm) hence negligible HAZ - Heat Affected Zone.
● EBM can be used for very accurate cutting or boring of a wide variety of metals.
● Reverse tapper can also be performed below the surface of the workpiece material.

Disadvantages
● Low MRR compared to conventional machining processes.
● Produces hazardous x-rays,
● Maintaining perfect vacuum is very difficult.
○ Suitable only for small workpieces.
○ Increases the cost for large workpieces.
● The machining process can’t be seen by operator.
● Trained professionals are needed to operate.
● Only electrically conducting materials can be machined.
● Very high equipment cost
● Need for secondary backing materials.

Applications
● Used for producing very small size holes like holes in diesel injection nozzles, Air brakes etc.
○ Used only for circular holes.
● Drilling holes in the aircraft engine, nuclear reactor etc.
● We can see small cross sectional area in the wire drawing die-machines.
● Electron beam is used for annealing, welding or metal removal by heating.

Extra points:
● High-energy pulses (in excess of 100 J/pulse) can machine larger holes on thicker plates.
● The energy density & power density is governed by energy per pulse duration & spot size.
● The plane of focusing would be on the surface of the workpiece or just below the surface of
the work piece.