Performance of Copper Tungsten Electrode on Alluminium Alloys LM6 in Die Sinking Using Factorial

Method

Abstract
The purpose of this project is to study the effect of EDM die sinking parameters on machining
characteristics for aluminium LM6 using copper tungsten electrode. The input parameters evaluated
are peak current, pulse on time and pulse off time. While, the output responses are material removal
rate, electrode wear rate, surface roughness and surface appearance. Full factorial design method
was applied to design the run matrix order. This method is able to identify the main effect and
interaction between the factors without any confounding. The analysis was done by using Minitab
software. The analysis of variance (ANOVA) was done in order to get the significant parameters and
optimize combination of the parameters. The expected result of this project that the peak current
will be the most significant factor followed by pulse on time and pulse off time. Meanwhile, the most
significant interaction factor for MRR and EWR is between peak current and pulse on time. While, for
surface roughness the most significant interaction factor is between peak current and pulse off time.
Thus, with high peak current, the higher rate of melting workpiece occurred at crater this is because
of energy current like a thunder shoot on the workpiece surface of aluminium LM6.