v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables viii
List of Figures x
List Abbreviations, Symbols and Nomenclatures xii
CHAPTER 1: INTRODUCTION 1
1.1 Background of the Project
1 1.2
Problem Statement 3
1.3 Objectives
3 1.4
Scopes 4
1.5 Outline of the Report
4
CHAPTER 2: LITERATURE REVIEW 5
2.1 EDM Machining Operations
5 2.1.1
Types of EDM Machines 7
2.1.2 EDM Die Sinking
9 2.2
EDM Machining Parameters 11
2.3 EDM Characteristics
14 2.3.1
Material Removal Rate MRR 14
2.3.2 Electrode Wear EWR
15 2.3.3
Surface Roughness Ra 16
2.3.4 Texture and Cracking of Craters
18 2.4
Material Workpiece 19
2.5 Types of Electrode
19 2.5.1
Copper 20
2.5.2 Graphite
20
vi 2.5.3
Tungsten Carbide 21
2.5.4 Cooper Tungsten
21 2.5.5
Iron 21
2.6 Design of Experiment DoE
22 2.6.1
Taguchi Method 22
2.6.1.1 Signal to Noise SN Ratio
23 2.6.1.2
Response to Signal to Noise SN Ratio 24
2.6.1.3 Analysis of Variance ANOVA
24 2.7
Summary 25
CHAPTER 3: METHODOLOGY 26
3.1 Experimental Setup
26 3.1.1
Current Experimental Setup 28
3.2 Specimen Preparation
30 3.3
Electrode Preparation 31
3.4 Experimental Parameters
32 3.5
Design of Experiment DoE 34
3.5.1 Taguchi Method Using Minitab English Version Sixteen
37 3.6
Summary 39
CHAPTER 4: RESULT AND DISCUSSION 40
4.1 Experimental Data
40 4.1.1
Selection of Factor Using Taguchi Method Design 40
4.1.2 Selection of Factor Level
41 4.1.3
Selection of Orthogonal Array OA 41
4.2 Result of the Experiment
42 4.3
Analysis of the Result 44
4.4 Analysis Result of Surface Roughness Ra Response
44 4.4.1
Signal to Noise Ratio Response of Ra 44
4.4.2 Signal to Noise Ratio Plot for Ra
45 4.4.3
Validation for Ra 46
4.5 Analysis of Variance ANOVA for Ra
47 4.6
Overall Result of Ra 50
vii 4.7
Analysis Result of Material Removal Rate MRR Response 51
4.7.1 Signal to Noise Ratio of MRR
52 4.7.2
Signal to Noise Ratio Plot for MRR 52
4.7.3 Validation for MRR
53 4.8
Analysis of Variance ANOVA for MRR 54
4.9 Overall Result of MRR
57 4.10
Analysis Result of Electrode Wear Rate EWR Response 58
4.10.1 Signal to Noise Ratio of EWR
58 4.10.2
Signal to Noise Ratio Plot for EWR 59
4.10.3 Validation for EWR
60 4.11
Analysis of Variance ANOVA for EWR 60
4.12 Overall Result of EWR
63 4.13
Surface Crater Observation 64
4.13.1 Surface Crater of the Smooth Surface
64 4.13.2
Surface Crater of the Rough Surface 65
CHAPTER 5: CONCLUSION AND FUTURE WORK 66
