Effect Of EDM Die Sinking Parameters On The Material Characteristics Of Aluminium Alloy LM6 Using Graphite Electrode

Nor Atiqah , Jaafar Sidek (2013) Effect Of EDM Die Sinking Parameters On The Material Characteristics Of Aluminium Alloy LM6 Using Graphite Electrode. Project Report. UTeM, Melaka. (Submitted)

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Abstract

EDM die sinking is a widespread process which works very effectively in the machining of micro holes, deep holes and harder material with high dimension accuracy. In this study, the objective is to optimize the machining parameters of the EDM process including peak current (Ip), machining voltage (V), pulse ontime (TOn) and pulse off-time (TOff) for increasing the material removal rate (MRR), reducing the electrode wear rate (EWR) and surface roughness (Ra) and finally investigating the craters of the workpiece. EDM machine model SODICK (AQ35L) was used in this project and the weight of the workpiece and electrode was measured using the analytical balance (METTLER TOLEDO). The MRR and EWR were calculated after experimental work. Graphite was used as an electrode to machine the Aluminium Alloy LM6, which is a composite of aluminium silicon alloy. Design of experiment (DOE), using Taguchi method has been applied in this project at three levels (high; +1, medium; 0 and low; -1) and there are 9 experiments were done with three repetitions. From the result of S/N ratio, the maximum MRR is 0.694841g/s. The lower EWR and Ra is 0.000065g/s and 2.52μm. Analysis of variance (ANOVA) results shows that Ip is the most significant parameter for this experiment. The results is MRR with 58.57% folowed by EWR with 55.57% and Ra with 97.56%. Thus, higher peak current produced higher MRR and surface roughness is low if the peak current also in low value. In terms of EWR in EDM, when using graphite as an electrode, it will increase the EWR.

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