v
TABLE OF CONTENT
Abstract i
Table of content iv
List of Figures x
List of Tables ix
List Abbreviations, Symbols and Nomenclatures vi
CHAPTER 1: INTRODUCTION
1.1 Project Background 1
1.2 Problem Statement 2
1.3 Objectives 3
1.4 Scope 4
1.5 Report Outline 4
CHAPTER 2: LITERATURE REVIEW
2.1 Introduction 5
2.2 Principle of Electrical Discharged Machine EDM 6
2.3 Dielectric Fluid 7
2.3.1 Flushing 8
2.4 Inconel 718 8
2.5 Copper Electrode 9
2.6 Surface Roughness Parameter 10
2.6.1 Peak Current and Pulse Duration against Ra 12
2.6.2 Pulse ON and Pulse OFF time 12
2.7 Measuring Surface Roughness 13
2.7.1 Duty Factor 14
2.7.2 Bottom and Side Wall surface 14
vi 2.8 Difference between Ra and Rz
15 2.9 Response Surface Modelling
17
CHAPTER 3: RESEARCH METHODOLOGY
3.1 Introduction 21
3.2 Work Planning 21
3.2.1 Flow chart 24
3.3 Apparatus Equipment and Machine 25
3.4 Material Selection 27
3.4.1 Work Material 27
3.4.2 Machine Tool 28
3.4.3 Preparation of the working tool Tool roughness 29
3.5 Experiment set up 30
3.5.1 Operating Parameter 30
3.5.2 Historical Data 32
3.6 Data Collection 32
3.6.1 Measure of Surface Roughness Ra 32
3.6.2 Measuring Method 33
3.7 Data Analysis 33
3.7.1 Analysis of Variance ANOVA 34
3.7.2 Diagnostic 34
3.7.3 Model Graph 35
3.7.4 Optimization 35
3.7.5 Validate data
CHAPTER 4: RESULT AND DISCUSSION
4.1 Introduction 36
4.2 Data Collection 36
4.2.1 Experiment Results 38
4.2.2 Surface Profile for minimum and maximum surface roughness 38
4.2.3 Analysis of Variance ANOVA 39
4.2.4 Variance Analysis of surface roughness of Inconel 718 40
4.3 Mathematical Model 41
4.3.1 Model of Surface Roughness of Inconel 718 43
vii 4.3.2 Excluding the outlier
45 4.4 Factor affecting surface roughness
46 4.4.1 Pulse ON time and Pulse OFF time
46 4.4.2 Discharge Current
48 4.5 Optimizing of Machining Parameters
49 4.5.1 Optimization Parameter of the surface roughness
40 4.5.2 Validation of the optimized parameter
52 4.5.3 Surface Profile for optimization and validation
52 4.6 Effect of tool roughness towards the surface finish
53 4.7 Comparison between the desired Ra the actual Ra
55 4.8 Sustainable Development
57
CHAPTER 5: CONCLUSION
