iv
TABLE OF CONTENTS
TITLE PAGES
ABSTRACT i
ACKNOWLEDGEMENT iii
TABLE OF CONTENTS iv
LIST OF FIGURES vii
LIST OF GRAPHS ix
LIST OF TABLES x
CHAPTER 1: INTRODUCTION
1.1 Background
1 1.2
Objectives 3
1.3 Scope of Project
4 1.4
Problem Statement 5
CHAPTER 2: LITERATURE REVIEW
2.1 Introduction
6 2.2
General Operating Principle of EDM 10
2.2.1 Process Mechanism
14 2.2.1.1
Illustration 1 14
2.2.1.2 Illustration 2
15 2.2.1.3
Illustration 3 16
2.2.1.4 Illustration 4
16 2.2.1.5
Illustration 5 17
2.2.1.6 Illustration 6
17 2.2.1.7
Illustration 7 18
2.2.1.8 Illustration 8
19 2.2.1.9
Illustration 9 20
2.2.2 Advantages of EDM
21 2.2.3
Limitation of EDM 21
v 2.3
Dielectric Fluid 22
2.4 The Types of EDM Usage
26 2.4.1
Micro EDM 27
2.4.2 EDM Drilling
28 2.4.3
Wire EDM 29
2.4.4
Abrasive Electro Discharge Grinding AEDG 30
2.5 Electrode
31 2.5.1
Copper Electrode 32
2.5.2 Graphite Electrode
33 2.5.3
Brass Electrode 34
2.5.4 Stainless Steel Electrode
35 2.6
EDM Machine Die Sinker 36
2.6.1 Introduction
36
CHAPTER 3: METHODOLOGY
3.1 Introduction 39
3.2 Research Methodology 39
3.3 Literature Review 41
3.4 Understanding the EDM Die Sinking and the Parameter 41
3.5 Tool and Workpiece Preparation 42
3.6 EDM Parameter Setup and Data Collection 42
3.7 Measurement Process and Data Collection 43
3.8 Discussion, Recommendation and Conclusion 45
3.9 Submitted Thesis and Final Presentation 45
CHAPTER 4: EXPERIMENTAL SETUP
4.1 Overview of the experiment 46
4.2 Experimental Equipment and Apparatus 47
4.2.1 EDM Machine 47
4.2.2 Machine Construction and Nomenclature 48
4.2.3 Description of Machine Components 49
4.2.4 EDM Machine Specification 51
4.2.5 Dielectric Tank Specification 53
vi 4.3 Copper Tool
53 4.3.1 Tool Properties
54 4.4 Workpiece
55 4.4.1 Workpiece Preparation
55 4.5 Machining Process
57 4.5.1 Experimental Procedure for EDM
57 4.6 Measurement Equipment
59 4.6.1 Dimensional Accuracy
59 4.6.2 3D Scanner
63 4.6.3 Surface Roughness Measurement
66
CHAPTER 5: RESULT AND DISCUSSIONS
5.0 Data Collections 68
5.1 Dimensional Accuracy on CMM 68
5.2 Dimensional Accuracy on Laser FaroArm Scanner 70
5.3 Surface Roughness 74
5.4 Side Overcut 79
CHAPTER 6: CONCLUSIONS AND RECOMMENDATIONS
