Question

how would you manfacture a 1mm hole 200mm deep and inside a metal block? (process) (introduction to manufacturing ,1st year engineering)

Answer 1

Capillary drilling is used to drill small and deep holes in hard, corrosion resistant metals. it is an acid electrolytic drilling technique and is also called as Electro Streaming and is a form of Electro Chemical Machinig (ECM)

Hole diameters as small as 0.2mm can be achieved, with depth to diameter ratio of 40:1 and multiple holes can be drilled simultaneously typically up to 100 holes.

The technology is rare and similar to electrical discharge machining (EDM) in that a high current is passed between an electrode and the part, through an electrolytic material removal process having a negatively charged electrode, a conductive fluid, and a conductive work piece.

There is little to no tool wear associated with this process and unlike EDM, however, no sparks are created. High metal removal rates are possible with Capillary Drilling, with no thermal or mechanical stresses being transferred to the part.

Other methods include

Laser machining