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...careful control of production parameters this can be reduced to 1–2°. Surface finish is usually in the range Ra = 1.6–3.2 µm but values Ra = 0.8 µm can be achieved. Smooth, burr-free cuts, free from contamination are produced although “dross” firmly attached to the underside of the cut can sometimes be a problem. Positional tolerances for hole and slot piercing...

...Careful design enables porosity to be “manipulated” to the least critical regions. External undercuts are possible. Complex internal shapes possible using disposable cores. Blind and through holes easy to incorporate; lateral holes by means of retractable cores. Tolerances of 0.2 mm 100 mm-1 possible before heat treatment. Wider tolerances advisable to allow for...

...careful control of the billet weight to within ±1%. Billets are either sawn or cropped to length. Cropped billets might require coining to eliminate crop and distortion. Before cold forging, billets have to be in their softest condition (fully annealed) and lubricated to prevent galling of the dies. Semi-continuous mesh belt furnaces with controlled atmospheres are used...

...careful control of operating conditions. Outside corner radii of 0.025 mm are possible, although inner corner radii are limited to 0.25–0.4 mm due to “overcut” during electrochemical reaction. Accuracies are typically ±0.025 mm on a one-pass cut, but ±0.005 mm can be achieved on the final pass without the use of electrolyte. See Also: Electrochemical machining and...