Influence of parameters on the overcut and surface roughness of deep cavity feature using EDM die sinking

Chia, Eileen Mei Ping (2014) Influence of parameters on the overcut and surface roughness of deep cavity feature using EDM die sinking. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

EDM is extensively used in the tool, mould, and dies industries as it is able to produce complex shapes regardless of the hardness of material. The objective of this study is to determine the effect of current (Ip), pulse on-time (Ton), pulse off-time (Toff), and depth of machining (D) on the overcut and surface roughness of deep cavity machining using EDM. It is also to develop mathematical modelling that defines the relationship between input parameters and output responses. The electrode used in this experiment was graphite ISO 63, and the workpiece used was AISI D2 steel. Experiments were conducted by SODICK NC Electrical Discharge Machine AQ35L, and the output response of diameter of cut was measured by using Zeiss coordinate measuring machine Contura G2 and calculated, whereas surface roughness was measured by using Mitutoyo SJ 301 portable surface roughness Tester. Full factorial Design of Experiment with two replications was used for experimental approach. The analyses carried out were the ANOVA, main effect, and interaction analysis. ANOVA results showed that pulse on-time (Ton) and depth of machining (D) were the most significant factors in affecting the overcut and surface roughness respectively. The mathematical modelling was also obtained from ANOVA.

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