Surface integrity of mild steel in die-sinking electrical discharge machine (EDM)

A comprehensive study of the surface integrity of the machined workpiece in the electrical discharge machining (EDM) of mild steel (AISI 1020) is presented in this thesis. Copper Electrode was used as a tools in this research. EDM is a thermal process that uses spark discharge to erode electrically...

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Main Author:	Muhamad Haniffah, Ghafar
Format:	Undergraduates Project Papers
Language:	English
Published:	2010
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://umpir.ump.edu.my/id/eprint/1491/ http://umpir.ump.edu.my/id/eprint/1491/ http://umpir.ump.edu.my/id/eprint/1491/1/Muhamad_haniffah_ghafar_%28_CD_5041_%29.pdf

id	ump-1491
recordtype	eprints
spelling	ump-14912015-03-03T07:51:22Z http://umpir.ump.edu.my/id/eprint/1491/ Surface integrity of mild steel in die-sinking electrical discharge machine (EDM) Muhamad Haniffah, Ghafar TJ Mechanical engineering and machinery A comprehensive study of the surface integrity of the machined workpiece in the electrical discharge machining (EDM) of mild steel (AISI 1020) is presented in this thesis. Copper Electrode was used as a tools in this research. EDM is a thermal process that uses spark discharge to erode electrically conductive materials, it’s primarily used for hard metals that very difficult to machine with traditional techniques. EDM tests on a mild steel workpiece were conducted on a sodick AQ55L (ATC) EDM Die-Sinking Machine. The surface Roughness tester Series Mahrsurf XR 20 is used to measure Ra and the surface microstructure was examined with a metallurgical microscopes. The EDM machining parameters those were used were peak current, IP (9A and 18A), discharge voltage (90V and 120V), servo voltage, SV (20V and 60V), pulse on-time (100μs and 300μs) and pulse off-time (500μs and 700μs). The full factorial design of experiment (DOE) from STATISTICA software was used to generate the arrangement of the experiment parameter and the software was used to analyze the effect of each parameter on the machining characteristics. From the analyzed result, peak current, IP and the pulse on-time have significant effect to the Surface Roughness, Ra. The lower values of these two parameters the lower Surface roughness, Ra observed. From the observation on the metallurgical microscopes, it is found there are clearly EDM damaged layer on the workpiece, distinguished by the width and length of microcrack and craters, especially at high peak current, IP and pulse on-time. The surface roughness, damaged layer and micro-cracks seem to decrease when the peak current and pulse on-time were set at very low values. 2010-12 Undergraduates Project Papers NonPeerReviewed application/pdf en http://umpir.ump.edu.my/id/eprint/1491/1/Muhamad_haniffah_ghafar_%28_CD_5041_%29.pdf Muhamad Haniffah, Ghafar (2010) Surface integrity of mild steel in die-sinking electrical discharge machine (EDM). Faculty of Mechanical Engineering, Universiti Malaysia Pahang. http://iportal.ump.edu.my/lib/item?id=chamo:52797&theme=UMP2
repository_type	Digital Repository
institution_category	Local University
institution	Universiti Malaysia Pahang
building	UMP Institutional Repository
collection	Online Access
language	English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Muhamad Haniffah, Ghafar Surface integrity of mild steel in die-sinking electrical discharge machine (EDM)
description	A comprehensive study of the surface integrity of the machined workpiece in the electrical discharge machining (EDM) of mild steel (AISI 1020) is presented in this thesis. Copper Electrode was used as a tools in this research. EDM is a thermal process that uses spark discharge to erode electrically conductive materials, it’s primarily used for hard metals that very difficult to machine with traditional techniques. EDM tests on a mild steel workpiece were conducted on a sodick AQ55L (ATC) EDM Die-Sinking Machine. The surface Roughness tester Series Mahrsurf XR 20 is used to measure Ra and the surface microstructure was examined with a metallurgical microscopes. The EDM machining parameters those were used were peak current, IP (9A and 18A), discharge voltage (90V and 120V), servo voltage, SV (20V and 60V), pulse on-time (100μs and 300μs) and pulse off-time (500μs and 700μs). The full factorial design of experiment (DOE) from STATISTICA software was used to generate the arrangement of the experiment parameter and the software was used to analyze the effect of each parameter on the machining characteristics. From the analyzed result, peak current, IP and the pulse on-time have significant effect to the Surface Roughness, Ra. The lower values of these two parameters the lower Surface roughness, Ra observed. From the observation on the metallurgical microscopes, it is found there are clearly EDM damaged layer on the workpiece, distinguished by the width and length of microcrack and craters, especially at high peak current, IP and pulse on-time. The surface roughness, damaged layer and micro-cracks seem to decrease when the peak current and pulse on-time were set at very low values.
format	Undergraduates Project Papers
author	Muhamad Haniffah, Ghafar
author_facet	Muhamad Haniffah, Ghafar
author_sort	Muhamad Haniffah, Ghafar
title	Surface integrity of mild steel in die-sinking electrical discharge machine (EDM)
title_short	Surface integrity of mild steel in die-sinking electrical discharge machine (EDM)
title_full	Surface integrity of mild steel in die-sinking electrical discharge machine (EDM)
title_fullStr	Surface integrity of mild steel in die-sinking electrical discharge machine (EDM)
title_full_unstemmed	Surface integrity of mild steel in die-sinking electrical discharge machine (EDM)
title_sort	surface integrity of mild steel in die-sinking electrical discharge machine (edm)
publishDate	2010
url	http://umpir.ump.edu.my/id/eprint/1491/ http://umpir.ump.edu.my/id/eprint/1491/ http://umpir.ump.edu.my/id/eprint/1491/1/Muhamad_haniffah_ghafar_%28_CD_5041_%29.pdf
first_indexed	2023-09-18T21:54:40Z
last_indexed	2023-09-18T21:54:40Z
_version_	1777413998685192192

Surface integrity of mild steel in die-sinking electrical discharge machine (EDM)

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