v
TABLE OF CONTENTS
ABSTARCT i
ABSTRAK ii
DEDICATION iii
ACKNOWLEDGEMENT iv
TABLE OF CONTENT v
LIST OF TABLES viii
LIST OF FIGURES ix
LIST ABBREVATIONS xi
1. CHAPTER 1
1.1 Introduction
1 1.2
Background of Problem: 2
1.3 Statement of Problem
3 1.4
Objective 3
1.5 Scopes
3 1.6
Importance of Study 4
1.7 Expected Result
4
2. CHAPTER 2
2.1 Electro Discharge Machining EDM Die Sinking
5 2.1.1
History Background 5
2.1.2 EDM Process
6 2.1.3
EDM Application 9
2.2 Electrode
10 2.3
Dielectric 11
2.4 White Layer
12 2.5
Surface Hardness 13
2.6 Properties of SKD11 Tool Steel AISI D2
14 2.7
Design of Experiment DOE 15
2.7.1 Full Factorial Design 15
vi 2.8
Summary of Journals Finding 17
3. CHAPTER 3 METHODOLOGY
3.1 Define the Objective of the Experiment
22 3.2
Identify the Parameter and Its Level 22
3.3 Identify the Appropriate Responds Variable
23 3.4
Identify the Orthogonal Array 23
3.5 Preparation of the Experiment
24 3.5.1 Preparation of Workpiece
24 3.5.2 Preparation of Electrode
24 3.5.3 Equipments and Procedures
25 3.6
Run Experiment 25
3.6.1 Testing 26
3.7 Analysis of the Data Collected From the Experiment Trials
26 3.8
Discussion on the Analyzed Data 27
3.9 Recommendation and Conclusion
27 3.10
Flow Chart of the Study 28
3.11 Flow Chart of Sample Preparation
29
4. RESULT AND DISCUSSION
4.1 White Layer Thickness
30 4.1.1 Cube Plot for White Layer Thickness
31 4.1.2 Interaction Plot for White Layer Thickness
32 4.1.3 Main Effect Plot for White Layer Thickness
33 4.1.4 Pareto Chart of the Effect for White Layer Thickness
35 4.1.5 Normal Probability Plot of Effect of White Layer Thickness
36 4.1.6 Normal Probability Plot of Residual for White Layer Thickness
37 4.1.7 Surface Plot and Contour Plot For White Layer Thickness
38 4.2
Surface Hardness 49
4.2.1 Cube Plot for Surface Hardness 40
4.2.2 Interaction Plot for Surface Hardness 41
4.2.3 Main Effect Plot for Surface Hardness 42
4.2.4 Pareto Chart of the Effects for Surface Hardness 44
vii 4.2.5 Normal Probability Plot of Effect for Surface Hardness
45 4.2.6 Normal Probability of Residuals for Surface Hardness
46 4.2.7 Surface Plot and Contour Plot For Surface Hardness
47 4.3
Discussion 48
4.3.1 White Layer Thickness 48
4.3.2 Surface Hardness 50
5. CHAPTER 3 METHODOLOGY
