Machinability and Eroding Techniques
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Questions and Answers

Which of the following metals CAN be machined using the Eroding method?

  • Aluminum (correct)
  • Steel (correct)
  • Brass (correct)
  • Wood
  • What is the primary factor influencing the machinability of steel?

  • The type of machining process used
  • The presence of manganese sulfide
  • The amount of lead added
  • The structure of the steel (correct)
  • In the context of steel machinability, what is the primary benefit of adding lead?

  • Increases the strength of steel
  • Increases the amount of manganese sulfide formed
  • Reduces friction and tool wear (correct)
  • Improves the hardenability of steel
  • Which of these is NOT a type of polishing?

    <p>Texture Finish (Texturpolitur) (C)</p> Signup and view all the answers

    What is the primary function of manganese sulfide in steel?

    <p>Increasing the strength of steel (D)</p> Signup and view all the answers

    Which of the following elements are commonly found in steel used in moulds?

    <p>S, Cr, Mo, Ni (D)</p> Signup and view all the answers

    What is the typical temperature range generated during the Eroding process?

    <p>8,000-12,000 °C (A)</p> Signup and view all the answers

    Which of the following factors influences the amount of material removed during the Eroding process?

    <p>All of the above (D)</p> Signup and view all the answers

    Which of the following is NOT considered an advantage of polishing moulds?

    <p>Increased mould durability (A)</p> Signup and view all the answers

    What type of material is typically used as a carrier or polishing tool?

    <p>Felt and Wood (B)</p> Signup and view all the answers

    What is the primary application of Eroding?

    <p>Creating complex shapes with high precision and tight tolerances (D)</p> Signup and view all the answers

    What is the key difference between Spark Eroding and Wire Cut Eroding?

    <p>The type of electrode used (B)</p> Signup and view all the answers

    What does the text suggest about the surface quality of moulds?

    <p>It should be accurate and good but only as necessary. (C)</p> Signup and view all the answers

    What are the two main types of coatings used for plastic molds?

    <p>Physical Vapor Deposition (PVD) and Chemical Vapor Deposition (CVD) (D)</p> Signup and view all the answers

    Which of the following is NOT a factor influencing the type of polishing used?

    <p>Cost of the mould (B)</p> Signup and view all the answers

    What percentage of total mould costs can polishing account for?

    <p>10-30% (D)</p> Signup and view all the answers

    What are some common mold components that can be coated to improve performance?

    <p>Both A and B (C)</p> Signup and view all the answers

    What is the unit used to measure surface roughness?

    <p>Micrometers (C)</p> Signup and view all the answers

    Which of the following is NOT a reason why molds are subjected to abrasive conditions?

    <p>Application of release agents (C)</p> Signup and view all the answers

    Which of the following is a common cause of reduced tool lifetime in injection molding?

    <p>All of the above (D)</p> Signup and view all the answers

    In the context of PVD, what is the process by which material is converted into a vapor?

    <p>Both B and C (A)</p> Signup and view all the answers

    How is material deposited onto the substrate in a PVD process?

    <p>Condensation of vapor (A)</p> Signup and view all the answers

    What is the key difference between PVD and CVD processes?

    <p>In PVD, material is deposited through a physical process, while in CVD, a chemical reaction is involved (C)</p> Signup and view all the answers

    In a CVD process, what happens to gaseous precursors on the substrate surface?

    <p>They react or decompose, leading to the formation of a solid film (C)</p> Signup and view all the answers

    Flashcards

    Quality of Steel

    Characteristics of steel based on its melt process and inclusions.

    Types of Polishing

    Different polishing techniques include stroke burnish, gloss finish, and mirror finish.

    Stroke Burnish

    A polishing technique that results in a matte finish.

    Gloss Finish

    Polishing technique that gives a shiny but not reflective surface.

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    Mirror Finish

    A highly reflective polishing technique achieving a perfect shiny surface.

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    Advantages of Polishing

    Enhances surface finish, aids demoulding, improves appearance, and prevents corrosion.

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    Surface Roughness

    Degree of irregularity on a surface measured in micrometers.

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    Cost Factor of Polishing

    Polishing can account for 10-30% of total mould costs, impacting overall pricing.

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    Coatings for Moulds

    Materials applied to moulds to enhance life and reduce wear.

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    Abrasive Wear

    Wear caused by hard particles scraping against surfaces.

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    Corrosive Wear

    Wear due to chemical reactions, such as acidic outgassing.

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    Frictional Wear

    Wear that occurs from sliding contact between parts during operation.

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    Injection Molding

    A manufacturing process for creating parts by injecting material into a mould.

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    Physical Vapor Deposition (PVD)

    A coating process that uses physical processes to deposit materials as vapor.

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    Chemical Vapor Deposition (CVD)

    A coating process using chemical reactions to deposit solid films.

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    Demoulding Release

    The ease with which a part is removed from its mould.

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    Machinability of Steel

    The ease of shaping steel using processes like turning, drilling, or milling, influenced by carbon content and alloying elements.

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    Lubricating Compounds

    Compounds like manganese sulfide that reduce friction during machining and improve hardenability of steel.

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    Low Carbon Steel

    Steel with low carbon and up to 1.5% manganese that enhances chip shape during machining.

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    Phosphorus in Steel

    Low concentrations of phosphorus improve chip breaking and surface quality during machining.

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    Lead in Low-Alloy Steels

    Lead added to low-alloy steels lowers melting point and forms a lubricating film, enhancing chip breaking and reducing tool wear.

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    Eroding

    A machining method where materials are removed using electrical discharge, producing high precision results.

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    Wire-Cut Eroding

    A type of eroding where a wire electrode cuts through a workpiece with high precision without contact.

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    Spark Eroding

    A process where sparks generated by electric discharge remove material, used for tight tolerances.

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    Study Notes

    Machinability of Steel

    • Machinability depends on steel's structure (affected by carbon content) and alloying elements.
    • Manganese sulfide compounds (MnS) improve strength, hardenability, and machinability.
    • Low carbon and 1.5% manganese content improves chip shape.
    • Phosphorus in low concentrations improves chip breaking and surface quality.
    • Lead is added to low-alloy steels, creating a lubricating film between the tool and chips. This reduces friction and tool wear, and improves chip breaking.

    Eroding

    • Material removal using electricity.
    • Two types: spark eroding and wire-cut eroding.
    • Both methods use an electrode near the workpiece.
    • Spark eroding creates a high temperature gap (8000-12000°C), causing material removal via discharges.
    • Wire-cut eroding moves a wire electrode close to the workpiece, and electric current creates a spark.

    Polishing of Moulds

    • Quality of steel affects polishing (processes like melt process and inclusions, and elements like S, Cr, Mo, Ni).
    • Specific steel types like 45 NiCrMo4 and 40 CrMnMoS 86 play a role.
    • Polishing factors include surface finishing, optical appearance, anti-corrosion, and scratch resistance.
    • Types of polishing include stroke burnishing, gloss finishing, and mirror finishing.
    • Polishing tools can be steel, brass, copper, felt, or wood.
    • Polishing can account for 10-30% of total mould costs.

    Coatings for Plastic Moulding

    • Moulds face high abrasion and corrosion from fillers, resins, sticking, and fretting.
    • Coatings improve mould life, reduce scrap, and improve demoulding processes.
    • Two major coating processes include physical vapor deposition (PVD) and chemical vapor deposition (CVD).

    Different Coating Processes (PVD and CVD)

    • PVD (Physical Vapor Deposition): Vaporization of material by physical processes like sputtering or evaporation.
    • Material is ejected from a target and deposited on a substrate.
    • PVD process is used to coat a variety of tools and components such as cutting, forming tools, moulds, mechanical components, medical devices, and products that would benefit from hard and decorative coatings.
    • PVD process is frequently used for depositing coatings made from nitrides, carbides, and carbonitrides of Ti, Cr, Zr, and Al alloys.
    • Material thickness: ~2-5µm
    • Process temperatures: ~ 250-450°C
    • Substrate materials: steels and non-ferrous metals.
    • CVD (Chemical Vapor Deposition): Chemical reactions to create a solid layer.
    • Gaseous precursors react to form a solid film on a substrate.
    • Precursors can be various materials suitable for coatings (e.g. titanium, tungsten, aluminum).
    • Coating thickness: ~ 2-3 µm.
    • Coatings can be conductive or non-conductive.

    PACVD (Plasma-Assisted Chemical Vapor Deposition)

    • Used for coating conductive and non-conductive materials at low temperatures (<200°C).
    • Creates amorphous coatings at specific thickness.
    • Uniform coating of 3D components without rotation.

    CVP (Chemical Vapor Process)

    • Process used for creating low stress coatings through thermally-induced reactions.
    • Material in vapor form reacts to create a thin film on a substrate.
    • Different temperatures and materials for different CVD types (HT & MT).
    • Materials are tungsten carbide, tool steel, HT-nickel alloys, and ceramic and graphite.
    • Suitable for parts in high-temperature applications

    CVA (Chemical Vapor Aluminizing)

    • Lowers costs, improves efficiency, and is environmentally friendly.
    • Coating process used for high-temperature applications.
    • Produces aluminide coatings on various materials such as blades, turbine components etc. This reduces oxidation and corrosion at high temperatures.

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    Description

    This quiz explores key concepts related to the machinability of steel, including the impact of alloying elements and the processes involved in erosion. Discover the significance of materials and techniques such as spark eroding and wire-cut eroding. Test your knowledge on how different factors influence the quality of steel and polishing of molds.

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