How do I produce a hole with a square cross section?

[nchin]

What are three different ways that i can produce a hole with a square cross section in a plate with a thickness of at least 1"?

 

[phinds]

Sounds like a homework question. Do you have any ideas yourself?

 

[nchin]

Sounds like a homework question. Do you have any ideas yourself?

Laser mill, water jet mill, drill/file?

 

[jedishrfu]

How about using a mold with a square in it and the pour the metal in it?

 

[phinds]

Those sound good. How about using a mold that creates the hole as the sheet is formed? I can't tell from the statement of the question whether that would be allowed or not, but I see that it might not.

There's also the plasma mill. A really massive punch press could probably do it.

 

[boneh3ad]

A wire EDM machine would get you really close; probably closer than any other method mentioned so far.

 

[256bits]

Oxy-acetylene torches or any of the other oxygen-gaseous fuels work fine also if tolerance is not a big issue.

 

[OCR]

All the answers here work good, but take a look on YouTube, also...

https://www.youtube.com/results?search_query=square+hole+drilling&page=1