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DM308 Non Traditional Manufacturing
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DM308 Non Traditional Manufacturing

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Questions and Answers

What is a key advantage of Wire-EDM compared to other methods?

  • Saves machining and material costs (correct)
  • Requires bulk electrodes
  • Ability to cut non-electrical-conductive materials
  • Inability to achieve fine geometries

    • Which material is Wire-EDM especially suitable for cutting?

  • Tungsten carbide (correct)
  • Silicon
  • Glass
  • Polymers

    • What are the common shapes achievable using EDM processes?

  • Flat surfaces only
  • Deep slots and narrow openings
  • Curved surfaces with intricate patterns
  • Cavities, slots, and holes (correct)

    • For what purpose might bulk-material removal be done before using EDM?

    <p>To improve surface roughness</p> Signup and view all the answers

    What is a limitation of EDM processes in terms of materials they can cut?

    <p>Cannot cut electrical conductors</p> Signup and view all the answers

    In the context of EDM processes, what is a suitable post-processing method often used after tool-making?

    <p>Grinding</p> Signup and view all the answers

    Why does high-rate EDM cutting lead to poor surface integrity?

    <p>Increased thermal stress and residual stress</p> Signup and view all the answers

    What is a characteristic of the wire used in Wire EDM?

    <p>Reused multiple times</p> Signup and view all the answers

    How does high surface finish impact the EDM process?

    <p>Requires high frequency of discharge</p> Signup and view all the answers

    What is an essential requirement for the wire used in Wire EDM?

    <p>High fracture toughness</p> Signup and view all the answers

    In Wire EDM, what is the typical travel speed range for the wire?

    <p>0.15-9 m/min</p> Signup and view all the answers

    What parameter is used to measure the removal rate in Wire EDM?

    <p>Cross-sectional area cut per unit time</p> Signup and view all the answers

    What are the applications of EDM to Moulds-making as mentioned in the text?

    <p>TV frames/covers, car panels, functional components of miniature/microdevices</p> Signup and view all the answers

    Why is maintaining the gap between the tool and the workpiece important in EDM?

    <p>To improve the surface finish of the component/part</p> Signup and view all the answers

    How does wire EDM work and why is it efficient and flexible compared to Die-sink EDM?

    <p>Wire EDM is efficient due to low power consumption and high cutting speed, Die-sink EDM is flexible due to its ability to handle complex geometries</p> Signup and view all the answers

    What is one of the significant influences on the EDM process and product quality?

    <p>Three parameters related to the EDM process</p> Signup and view all the answers

    Which roles does a dielectric fluid play in EDM?

    <p>To enhance electrical conductivity between electrode and workpiece</p> Signup and view all the answers

    How should an electrode material be selected for Die-sink EDM?

    <p>Based on its melting point and wear resistance properties</p> Signup and view all the answers

    What is the key function of a telescope in mask-based laser ablation?

    <p>To homogenize the laser radiation</p> Signup and view all the answers

    Which step in laser machining involves the projection of the laser onto a mask representing the desired intensity distribution?

    <p>Objective lens imaging stage</p> Signup and view all the answers

    In laser machining, what are the three surface/material parameters that significantly influence the process?

    <p>Conductivity, melting point, and thermal expansion</p> Signup and view all the answers

    Why is 3D laser cutting considered more efficient than single beam laser cutting?

    <p>It reduces heat-affected zones and distortion</p> Signup and view all the answers

    What are the main design considerations for laser-machining processes?

    <p>Laser power, focus depth, and pulse duration</p> Signup and view all the answers

    Compared to Chemical etching and EDM, what advantage does Laser machining offer in material processing capabilities?

    <p>Reduced material wastage and better edge quality</p> Signup and view all the answers

    What is the function of a Nd:YAG crystal in lasers?

    <p>Act as a lasing medium</p> Signup and view all the answers

    Which laser type is commonly used for welding metals?

    <p>PCO2</p> Signup and view all the answers

    What is the main application of a ruby laser?

    <p>Marking/Engraving metals</p> Signup and view all the answers

    In laser machining with two beams, what concept does the process emulate?

    <p>Grinding and turning actions</p> Signup and view all the answers

    What does CW in CWCO2 laser stand for?

    <p>Continuous Wave</p> Signup and view all the answers

    Which laser type is commonly used for microelectronic device production?

    <p>Excimer</p> Signup and view all the answers

    Which laser type is commonly used for surface treatment of metals?

    <p>PCO2</p> Signup and view all the answers

    What is the crystal used as a lasing medium for solid-state lasers?

    <p>Nd:YAG</p> Signup and view all the answers

    In laser machining, which laser type emulates the actions of a mechanical tool?

    <p>CWCO2</p> Signup and view all the answers

    What is the meaning of PC in PCO2 laser?

    <p>Pulsed CO2</p> Signup and view all the answers

    Which type of laser is commonly used for drilling plastics?

    <p>Excimer</p> Signup and view all the answers

    What does CW stand for in CWCO2 laser?

    <p>Continuous Wave</p> Signup and view all the answers

    Which laser type is suitable for marking and engraving ceramics?

    <p>Nd:YAG</p> Signup and view all the answers

    'Excimer' laser was originally short for what?

    <p>'Excited Dimer'</p> Signup and view all the answers

    What does Nd stand for in Nd:YAG laser?

    <p>Neodymium</p> Signup and view all the answers

    What is the main application of a ruby laser?

    <p>Welding Metals</p> Signup and view all the answers

    Study Notes

    • Applications of EDM in mould-making include microstructured referential workpieces, mould inserts for hot embossing micro opto-electronic connecting plugs, and microgears for micro planetary drives.
    • Moulds are widely used in manufacturing parts like mobile phone covers, TV frames, car panels, and functional components of miniature devices.
    • Die-sink Electro-discharge machining requires a dielectric fluid, proper gap maintenance between tool and workpiece, and careful selection of electrode material.
    • Wire EDM is more efficient and flexible compared to Die-sink EDM as it allows for finer geometry, controlled motion of the workpiece, drilling micro-size holes, and polishing fragile tools.
    • EDM process variants include Die-Sinking, WEDM, ED-Drilling, ED-Milling, EDG, and WEDG, suitable for cutting any electrical conductor material, especially hard metals like tool steels and tungsten carbide.
    • Micro/Nano-EDM allows for rough cutting, polishing, and grinding, with parameters like spark intervals, current density, and voltage influencing the process and product quality.
    • Wire EDM offers merits such as using no bulk electrodes, achieving high surface finish, and cutting materials with a wire diameter as small as 0.01mm.

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    Related Documents

    DM308 Part 5 Non Tradtional Manufacturing.pdf

    Description

    Test your knowledge on spark intervals, current density, voltage, and high-rate EDM cutting. Learn about the requirements, effects of high energy input, temperature, heat-affected zone, cooling rate, and surface integrity in high-rate EDM cutting processes.

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