Chemical milling is a metal removal process using chemical solutions to remove large amounts of metal for parts that cannot be easily machined. It is widely used in the aerospace industry due to precision engineering requirements. The process is simple and cost-effective, with advantages including low capital costs, rapid weight reduction, and minimal need for skilled labor. However, it can be difficult to machine very thick material or reach sharp corners, and etching solutions can be dangerous to work with.
Chemical milling or chemical machining is a metal removal process by applying strong chemical solutions to a metal surface. It is used to remove large amounts of metal to obtain parts that cannot be easily machined with traditional machining methods. Parts that require precision engineering, such as miniature micro-components or those that contain deep internal cavities, are just some of the components produced with chemical milling. While it has numerous applications in automotive manufacturing and electronics, it is widely used in the aerospace industry.
This processing method is considered to be one of the oldest non-traditional processing methods in existence. Chemical grinding was used in the 19th century for decorative engraving, and its application in industry came much later. Manuel C. Sanz, an engineer with the North American Aviation Company, is credited with solving a critical weight problem on a missile casing using the process. The company patented the process in 19.
The whole process is quite simple and involves cleaning and masking off the parts that don’t require engraving. The metal is then immersed in large vats of etching solution. The amount of material removed is controlled by the concentration of the chemical solution, the type of etchant used, the time spent in the tank and the temperature. An ultrasonic thickness gauge helps the operator regularly evaluate the thickness of the part until the thickness specified in the design is achieved. Etched parts are cleaned and inspected for quality control.
A large number of parts can be milled at once, making it an extremely cost-effective method of manufacturing parts. The primary use of chemical milling is to reduce the weight of the metal in shaped parts. Even complex shapes and protrusions can be engraved with the utmost precision. Many parts of commercial aircraft, launch vehicles, missiles and turbines are produced by chemical milling. Both small parts like cover plates and large parts like fuselage skins can be produced very easily.
It is one of the most popular crafting methods because it is quite simple, inexpensive and well established. The advantages of using this process over other machining methods are low capital and tooling costs, rapid weight reduction, and minimal need for skilled labor. In addition to making design changes easier to implement, it does not expose the metal to any additional stresses. The surface quality of the metal remains good and no burrs are formed during the process. The downsides are that it can be difficult to machine very thick material or reach sharp corners, and etching solutions can be dangerous to work with.
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