Process optimization for die manufacture : EDM die sinking

Jainudin, Mohd Irwan (2014) Process optimization for die manufacture : EDM die sinking. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Electrical Discharge Machining (EDM) is one of the Non-Traditional Machining processes, based on the thermo-electric energy between the workpiece and the electrode. In this process, material removal occurs by a series of electro-thermal relief between successive discrete electrode and the workpiece. The performance of the process, to a large extent, depends on the Electrode material. Electrical Discharge Machining (EDM) is a most popular machining method to manufacture dies, punches and press tools because of its capability to produce complicated, intricate shapes and to machine hard materials. SKD11 is a very commonly used material due to its property of resistant to corrosion. During experimentation, electrode material, current and pulse on time were taken as variables for the study of material removal rate and surface roughness. Two different electrode materials copper and brass were used. Using Taguchi method, Mixed Design L18 orthogonal array has been chosen and three levels corresponding to each of the variables are taken. Experiments have been performed as per the set of experiments designed in the orthogonal array. These experiments were analyzed by using Minitab software. From the result of analysis, electrodes were finding a most influent parameter for a surface roughness. Brass electrodes were found that give lower value than copper. Lowest value that gives while using Brass electrode is 1.53μm, which lower than using copper electrode that gives a value of 2.71μm. While current is the most influent parameter that affects the material removal rate. When current is 30A, its give more MRR than 10A and 18A. From this analysis also found the optimize equation for both surface roughness and material removal rate.

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