v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables ix
List of Figures xi
List Abbreviations, Symbols and Nomenclatures xiii
CHAPTER 1: INTRODUCTION 1
1.1 Background
1 1.2
Problem Statement 3
1.3 Objectives
3 1.4
Scopes 4
1.5 Outlines
4
CHAPTER 2: LITERATURE REVIEW 6
2.1 EDM Machining Operations
6 2.1.1
Types of EDM Machine 8
2.1.2 EDM Die Sinking
10 2.2
EDM Machining Parameters 12
2.2.1 Peak Current I
p
13 2.2.2
Machining Voltage V 14
2.2.3 Pulse ON Time t
off
14 2.2.4
Pulse OFF Time t
on
15 2.3
EDM Characteristics 15
2.3.1 Material Removal Rate MRR
15
vi 2.3.2
Electrode Wear EWR 16
2.3.3 Surface Roughness Ra
16 2.3.4
Texture and Cracking of Craters 16
2.4 Types of Electrode
17 2.4.1
Graphite Electrode 18
2.5 Material Workpiece
19 2.5.1
Aluminium Alloy LM6 Al-Sil2 19
2.6 Measuring Equipments
20 2.6.1
Surface roughness measurement 20
2.6.2 Crater Observation Equipment
20 2.6.3
Evaluation of EWR and MRR 21
2.7 Design of Experiment DOE
21 2.7.1
Taguchi Method 21
2.7.2 SN Ratio
23 2.7.3
Response to SN Ratio 23
2.7.4 Analysis of Variance ANOVA
24 2.8
Summary 25
CHAPTER 3: METHODOLOGY
26 3.1
Introduction 26
3.2 Flow Chart
27 3.3
Specimens Preparation 28
3.4 Electrode Preparation
28 3.5
Machines and Measurements Equipments 29
3.5.1 EDM Wire Cut Machine
29 3.5.2
EDM Die Sinking Machine 30
3.5.3 Surface Roughness Measurement
30 3.5.4
Optical Microscope 31
3.5.5 Analytical Balances
31 3.6
Experimental Parameters 32
vii 3.7
Experimental Setup 33
3.8 Design of Experiment DOE
34 3.8.1
Taguchi Method Using Minitab Software Version 16 34
CHAPTER 4: RESULTS DISCUSSION
37 4.1
Experimental Data 37
4.2 Results of the Experiment
39 4.3
Analysis of the Results 41
4.4 Analysis Results of Material Removal Rate MRR
41 4.4.1
SN Response of MRR 41
4.4.2 SN Response Plot of MRR
43 4.4.3
Analysis of Variance ANOVA for MRR 45
4.4.4 Validation of Parameters for MRR
46 4.5
Analysis Results of Electrode Wear Rate EWR 47
4.5.1 SN Response of EWR
47 4.5.2
SN Response Plot of EWR 49
4.5.3 Analysis of Variance ANOVA for EWR
50 4.5.4
Validation of Parameters for EWR 51
4.6 Analysis Results of Surface Roughness Ra
52 4.6.1
SN Response of Ra 52
4.6.2 SN Response Plot of Ra
54 4.6.3
Analysis of Variance ANOVA for Ra 56
4.6.4 Validation of Parameters for Ra
57 4.7
Surface Craters Observation 58
4.7.1 The Smallest Craters Diameter
58 4.7.2
The Biggest Craters Diameter 59
CHAPTER 5: CONCLUSION RECOMMENDATIONS 61
