Effect Of EDM Die-Sinking Parameters On The Material Characteristics Of Aluminium Alloy LM6 Using Cooper Tungsten

Nor Halida Ilyani, Kamarudin (2013) Effect Of EDM Die-Sinking Parameters On The Material Characteristics Of Aluminium Alloy LM6 Using Cooper Tungsten. Project Report. UTeM, Melaka. (Submitted)

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Abstract

Forming deep area by arc erosion in all kind of electro conductive material. It is one of the non-traditional machining processes that involved a transient spark discharges through the fluid due to the potential difference between the electrode and the work piece. EDM is most used where intricate complex shapes need to be machined in very hard materials such as hardened tool steel. This paper presents a fundamental study of characteristics of electrode discharge machine (EDM) that are electrode wear ratio (EWR), material removal rate (MRR), surface roughness (Ra), and appearance observation. The experiment was done using SODICK AQ35L EDM machine. Design of experiment (DOE) using taguchi method was applied to design the experimental number of trials, and analyze the significant factors that affecting the machining characteristics for EDM process. Total of nine experiments were conducted with each repeated three times. The results obtained from this research shows that current, pulse on time and pulse off time were the most significant factor effecting the EDM machining characteristics. The optimum parameters for this experiment which are current with level 1 followed by pulse on time of level 2 and level 3 pulse off time. It will support with the percentage of contribution using analysis of variance (ANOVA) of MRR, current 62.57%, pulse on time 36.10% with 23.41% pulse off time. Then, for EWR, current 57.35% with 25.31% of pulse on time and pulse off time 14.11%. Lastly, for Ra the percentage for current is 99.85%, pulse on time 17.13% with 0.10% pulse off time. Thus, the flow of current melting the workpiece that’s why the current was the significant factor.

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