SUBJECT: SPARK EROSION AND COPY MILLIG

ASSIGNMENT :01
SELECTION APPLICATION

ADDVANTAGE PROCESS

DISADVANTAGES ELECTRODES
 Q1: Define spark erosion and its application?
 ANS: SPARK EROSION:
Spark Erosion machining is a method used when machining
challenging pieces with intricate detail. The process involves both the workpiece
and the tool being connected to a direct current; this provides a
constantspark between the two.

APPLICATION:
1:Machinists 2:Mold makers or 3:Used for hard metals
also use sparkers to toolmakers use any and metals that are
work on car parts. shape such as a difficult to machine
simple cylinder or a using traditional
polygon. methods.
 Q:2 Define theory of single spark?
 ANS: THE THEORY OF SINGLE SPARK:
The spark erosion process is a very simple one
or a very difficult one to understand. It all depends to what extent you want to know
about it . The very simple explanation is that when two wires under tension are
brought close to each other, at a certain distance (depending on the voltage) an
electric spark occurs and tips of both wires are somehow eroded.
This very simple explanation wouldn’t have
helped the scientist to develop these to sophisticated machines which are available
today.
 Q3: How to make electrode?
 ANS: PROCESS:
Separate the cathode and anode with a layer of paper and place
them in a metal container. Seal the container to make the battery.
Include electrodes as part of a secondary cell, such as a rechargeable battery. The
manufacture of electrodes in secondary cells is similar to that of electrodes in
primary cells.
Q4: Advantages and disadvantages of spark erosion?

ADVANTAGES DIS ADVANTAGES

 Passive fit of restorations is achieved.  Eroding tends to affect the corrosion

 Complex 3-dimensional structures can resistance of titanium.
be shaped regardless of metal
hardness since it is a thermal process.  Skilled personnel and specialized
 An extremely thin work piece can be lab equipment is mandatory.
machined without distortion as no
mechanical forces are created.  The high cost of the technique limits
its usage.
 There is decreased stress on the work
piece due to the cooling action of the
di-electric fluid.
 Smooth finish of final restoration is
ensured.
 Q5: How to select the electrode material?
 ANS: ELECTRODE MATERIAL:
ELECTRODE FORM OPERATION APPLICATION WORKPIECE
MATERIAL MATETIAL
• Copper Solid,tube,bar,cast Rouging to fine all All metals
,wirestamping finishing

• Copper - Bar,wire,tube, Roughing to Holes,slots,moulds All metals

solid finishing ,dies
tungsten
• Brass Tube,solid roughing Holes,wires,cut All metals

• Tungsten Flat,rod,wire Semi_fininshing to Deep holes wire- Difficult to

roughing cut small slot machine metals

• Aluminiu Cast,forged roughing Forging dies steel

m
• Graphite Solid small rods Roughing to All tooling steel
finishing

• Graphite solid fininshing All toooling steel

copper
• Steel All Roughung Holes stamping • steel
dies
APPLICATIONS MILLING ENGRAVING

DIFFRENTIATE TEMPLATES
 Q1: Define copy milling and its application?
 ANS: COPPY MILLING:
The copy mill is a simple variation on the traditional end mill, in
that the copy mill uses circular insert geometry as opposed to traditional parallelogram
or square inserts.
 APPLICATION:
Copy milling. The traditional and easiest method for programming tool
paths for a cavity is to use the normal copy milling technique, with many entrances and
exits into the material. However, this means that powerful software
programs, machinesand cutting tools are used in a very limited way.
• Q2: Differentiate between copy milling and engraving?
• ANS: DIFFERENTIATE:
COPY MILLING
 The copy mill is a simple variation on
the traditional end mill, in that
the copy mill uses circular insert
geometry as opposed to traditional
parallelogram or square inserts.
 Copy milling machines are used for
machining pump vanes and turbine b
lades, ship propellers, cams, dies, pre
ss molds,sculptures, and jewelry.
ENGRAVING
 a machine for
mechanical engraving from a
drawing, stencil, or model.
Anengraving machine is used to
transfer representations from bas-
reliefs and other convex artistic
originals to soft metal (such as
copper), stone, or wood. ...
Anengraving machine is used in
polygraphy to prepare zincographic
stereotypes.
 Q3:Describe two dimensional engraving machine?
 ANS: TWO DIMENSIONAL ENGRAVING MACHINE:
A machine for mechanical engraving from a drawing, stencil, or model. An engravin
g machine is used to transferrepresentations from bas-
reliefs and other convex artistic originals to soft metal (such as copper), stone, or wo
od. Inmetalworking the engraving machine is a small copying-
milling machine with a pantograph, carrying a cutting instrument(cutter or graver),
which cuts the stamps, inscriptions, and figures on machined parts. An engraving ma
chine is used inpolygraphy to prepare zincographic stereotypes.
 Q4: Copy milling tamplates?
 ANS: COPPY MILLING TAMPLATES:
Templates are mainly made of sheet metal mild
steel or brass on which the required shape is machined. Many copy milling problem
can be solve wit the help of templates only. The most prominent advantage of
templates is, that they can be produced to an enlarged scale,hence the accuracy on
the work piece is increased.
THANK YOU