Materials Shaping

These flashcards cover key concepts regarding materials shaping, specifically focusing on EDM and casting processes.

EDM (Electrical Discharge Machining)

A non-contact thermal erosion process between an electrode and a workpiece submerged in dielectric fluid.

Conventional Machining

A metal removal method based on contact between a cutting tool and a workpiece.

Automotive Stamping Dies

The largest application for EDM machining, used to make 1-piece dies from hardened tool steel.

Advantages of EDM Machining

Includes the ability to machine brittle materials, produce intricate details, and reduce part damage.

Disadvantages of EDM Machining

Includes slower metal removal rates, conductive workpiece requirements, and consumable electrodes.

Dielectric Fluid

Fluid that introduces clean conditions, flushes away debris, and cools both workpiece and electrode in EDM.

Wire EDM

A process using a thin wire to cut shapes from hardened tool steel with continuous operations.

Schematic of Hot Chamber Die Casting

A diagram that details die casting components including plunger, fixed die, and molten metal.

Investment Casting

An expendable mould/expendable pattern process involving wax patterns that are melted to form mould cavities.

Refractory Metals

Metals that resist heat and wear, commonly used in electrical and catalytic applications.

Maraging Steel

Iron alloys known for high strength and toughness; derived from intermetallic compounds.

Centrifugal Casting

A casting process that uses centrifugal force to achieve increased density in the final product.

Casting Core

A component used to create recesses and interior features in castings.

Family Dies

A die that holds moulds for multiple parts that are cast simultaneously for assembly.

Vents in Die Moulds

Features that allow air to escape during casting, thereby minimizing porosity defects.

Sand Moulding

A casting process using expendable moulds made from sand, allowing for various sizes at lower costs.

EDM Process Variables

Factors like peak amperage and length of on-time that affect the metal removal rate and surface finish.