v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables ix
List of Figures xi
CHAPTER 1: INTRODUCTION 1
1.1 Background
1 1.2
Problem Statement 2
1.3 Objectives
3 1.4
Scope of Work 3
CHAPTER 2: LITERATURE REVIEW 4
2.1 Machining
4 2.2
Traditional Machining 5
2.2.1 Machining by Cutting 6
2.2.2 Machining by Abrasion 8
2.3 Non-Traditional Machining
9 2.3.1 Single-Action Non-Traditional Machining
10 2.3.1.1 Mechanical Machining
10 2.3.1.2 Thermal Machining
11
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2.3.1.3 Chemical and Electrochemical Machining 12
2.4 Electro Discharge Machining EDM
13 2.4.1 EDM Die-Sinking
14 2.4.2 Working Principle of EDM
15 2.4.3 The Machining System
18 2.4.4 Dielectric Fluid
19 2.4.5 Flushing
20 2.4.5.1 Normal Flow
20 2.4.5.2 Reverse Flow
21 2.4.5.3 Jet Flushing
21 2.4.5.4 Immersion Flushing
21 2.5
Advantages and disadvantages of EDM die-sinking 22
2.6 Applications
22 2.6.1 Drilling
23 2.6.2 Sawing
23 2.6.3 Machining of Spheres
24 2.6.3 Machining of Dies and Mold
24 2.7
EDM Electrode 25
2.7.1 Brass 25
2.7.2 Copper 26
2.8 Material of Workpieces
28 2.8.1 SKD11 Alloy Tool Steel
28 2.9
Parameter EDM Die-Sinking 29
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2.10 Machining Performance
30 2.10.1 Material Removal Rate MRR
30 2.10.2 Surface Roughness Ra of Workpieces
31
CHAPTER 3: METHODOLOGY 32
3.1 Flow Chart
32 3.2
Specimen Preparation 35
3.3 Electrode Preparation
36 3.4
Machine and Measurement Equipment 37
3.4.1 EDM Wire Cut Machine 37
3.4.2 EDM Die-Sinking Machine 37
3.4.3 Surface Roughness Measurement 39
3.5 Design of Experiment and Data Analysis
39
CHAPTER 4: RESULTS AND DISCUSSIONS 45
4.1 Experimental Matrix and Experimental Result of the EDM Parameters
45 4.1.1 Process control parameters
45 4.1.2 Design Matrix of Process Control Parameters and the Response
46 4.1.3 The Surface Microstructure
48 4.2
Analysis of the EDM Parameters to Surface Roughness and Material Removal Rate
49 4.2.1 Surface Roughness Ra
51 4.2.1.1 Analysis of Variance for Surface Roughness Ra
51
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4.2.1.2 Determine Optimum Factor-Level Combination 52
4.2.1.3 Optimize Performance for Ra 53
4.2.2 Material Removal Rate MRR 55
4.2.2.1 Analysis of Variance for MRR 55
4.2.2.2 Determine Optimum Factor-Level Combination 56
4.2.2.3 Optimize Performance for Ra 57
CHAPTER 5: CONCLUSIONS AND RECOMMENDATION 59
