Novel EDM Screw Threading Technique Using Threaded Cavity Electrode

Ahmad Hisyamuddin , Hassan (2013) Novel EDM Screw Threading Technique Using Threaded Cavity Electrode. Project Report. UTeM, Melaka. (Submitted)

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Abstract

The complicated geometrical design and tight tolerance of orthopedic screw such as titanium alloys were fabricated using single-point threading and thread whirling technique. However, there are few problem encounters with these techniques such as rapid tool wear, limited design flexibility, low accuracy and high capital cost. The suitable candidate to overcome this problem is using Electrical Discharge Machining (EDM) process in which the material is removed by spark erosion. Since there is no physical contact between tool electrode and workpiece, the tool wear rate is low and the material hardness is not dependent. In addition, the main advantages of using EDM technique are the accuracy and fine surface integrity which is suitable for medical application. However, to ensure the success of EDM as an alternative manufacturing technique for orthopedic screw required a scientific investigation especially on the effect of EDM machining parameter. This study aims to investigate the effect of EDM machining parameter namely current, pulse on time and pulse off time on machining performances. A statistical response surface methodology are use to evaluate the effect of the machining parameter on the machining performances namely surface roughness, machining time and electrode wear. Lastly, the optimal machining condition base on the multi-objective performance criteria will be proposed.

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