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

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Discussion Overview

The discussion revolves around methods to produce a hole with a square cross section in a plate with a thickness of at least 1 inch. Participants explore various techniques and tools applicable to this task.

Discussion Character

  • Homework-related
  • Technical explanation
  • Exploratory

Main Points Raised

  • Some participants suggest using a laser mill, water jet mill, or drill/file as potential methods.
  • Another participant proposes using a mold with a square shape to cast the metal.
  • There is a suggestion to use a mold that creates the hole during the sheet forming process, though uncertainty exists about whether this method is permissible based on the question's wording.
  • A plasma mill is mentioned as another viable option for creating the hole.
  • A wire EDM machine is noted for its precision in achieving the desired shape.
  • Oxy-acetylene torches or other oxygen-gaseous fuels are mentioned as alternatives, particularly if tolerance is not a critical factor.
  • One participant encourages looking for additional methods or demonstrations on YouTube.

Areas of Agreement / Disagreement

Participants present multiple competing views on the methods to achieve the desired hole shape, with no consensus on a single best approach. The discussion remains unresolved regarding the best technique.

Contextual Notes

Participants express varying degrees of certainty about the appropriateness and effectiveness of each method, and some methods may depend on specific conditions such as tolerance requirements.

nchin
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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"?
 
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Sounds like a homework question. Do you have any ideas yourself?
 
phinds said:
Sounds like a homework question. Do you have any ideas yourself?

Laser mill, water jet mill, drill/file?
 
How about using a mold with a square in it and the pour the metal in it?
 
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.
 
A wire EDM machine would get you really close; probably closer than any other method mentioned so far.
 
Oxy-acetylene torches or any of the other oxygen-gaseous fuels work fine also if tolerance is not a big issue.
 

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