Surface Integrity Study In EDM Die Sinking Process

Noor Aizah , Mahat (2011) Surface Integrity Study In EDM Die Sinking Process. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

This project was discussed about 4 parameters that can be effect the performance of EDM Die Sinking while machining mild steel by using copper electrode with dimension of 10 mm × 10 mm. The main purpose of this study is to investigate the effect on machining characteristics of Surface Roughness, Crack Density and White Layer Thickness which influenced by the machining parameters set up. Design of Experiment (DOE) had applied for this experiment. Taguchi method had chosen to formulate the experimental layout and analyze the effect of each parameters on machining charcteristics and predict optimal setting for parameters like Peak Current (IP), Pulse ON Time (ON), Pulse OFF Time (OFF), and Voltage (V). Taguchi method was approach by three levels and 4 parameters. All the results had do confirmation by using Analysis of Variance (ANOVA). In this investigation, Die Sinking EDM AQ35L was used to do machining. However, Mitutoyo Surface Roughness Tester, SJ.301 was used for measuring the surface roughness while Scanning Electron Microscopy, EVO 50 was used to measure white layer thickness and crack density. Besides than that, confirmation tests were done to do comparison with the predicted result. For the result, peak current and voltage is the primary significant effect to the machining chracteristics investigated especially the surface roughness.

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