Performance Of Copper Tungsten Electrode On Aluminium Alloys LM6 In Die Sinking Using Full Factorial Method

Wan Saharuddin, Wan Nurulhezaty (2019) Performance Of Copper Tungsten Electrode On Aluminium Alloys LM6 In Die Sinking Using Full Factorial Method. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Electrical discharge machining (EDM) die sinking is the one of the important process in manufacturing industry for cutting high hardened material by an arc erosion in all kind of electron conductive materials. The machining parameter is an important role in order to determine the good quality for the surface integrity of the product. The purpose of this project is to study the effect of EDM die sinking parameters related to the machining characteristics for aluminium alloys LM6 using full factorial method. The input parameter assess are pulse on time, pulse off time and current. Meanwhile, this project presents fundamental study of the machining characteristics that are material removal rate (MRR), electrode wear rate (EWR), surface roughness (Ra) and observation the cracking of crater. The design of experiment (DOE) using full factorial method was applied to design the run matrix order by 2 levels with 3 factors. The result of this project shows that the current factor is the most significant parameters followed by pulse on time and pulse off time. Meanwhile the single optimization for maximize the value of MRR is 0.3375, for minimize the value of EWR is -0.0003 and also minimize the value of Ra is 0.6386. Further, multi optimization is set to minimize the value of Ra and EWR with maximize the value of MRR. It is found that. The multi optimization value that been obtained are 25.14A for current, 400μs for pulse on time, 1μs for pulse off time, having output 0.269724g/min for MRR, 0.00416228g/min for EWR and 2.18403μm for Ra with the desirability is 0.576. Therefore, the current is the most significant factor. It is because the high value of current increases the rate of melting work piece.

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