Investigation on different composition of powder metallurgy electrode (Cu-W) in high performance edm (HPEDM) on AISI D2 hardened steel

The ideal selection of manufacturing conditions is one of the most important aspects to take into consideration in the majority of manufacturing processes and particularly in processes related to Electrical Discharge Machining (EDM). EDM die sinking machines are used to machine conductive meta...

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Main Author:	Abdul Hamid, Faizul Ezmat
Format:	Thesis
Language:	English English English
Published:	2013
Subjects:	TJ Mechanical engineering and machinery TJ1125-1345 Machine shops and machine shop practice
Online Access:	http://eprints.uthm.edu.my/1899/1/24p%20FAIZUL%20EZMAT%20ABDUL%20HAMID.pdf http://eprints.uthm.edu.my/1899/2/FAIZUL%20EZMAT%20ABDUL%20HAMID%20COPYRIGHT%20DECLARATION.pdf http://eprints.uthm.edu.my/1899/3/FAIZUL%20EZMAT%20ABDUL%20HAMID%20WATERMARK.pdf
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spelling	my-uthm-ep.18992021-10-12T04:31:54Z Investigation on different composition of powder metallurgy electrode (Cu-W) in high performance edm (HPEDM) on AISI D2 hardened steel 2013-05 Abdul Hamid, Faizul Ezmat TJ Mechanical engineering and machinery TJ1125-1345 Machine shops and machine shop practice The ideal selection of manufacturing conditions is one of the most important aspects to take into consideration in the majority of manufacturing processes and particularly in processes related to Electrical Discharge Machining (EDM). EDM die sinking machines are used to machine conductive metals of any hardness or difficult to machine with traditional methods. The problem in the capabilities of tool electrodes which are not utilized at the optimum levels of the operating parameters has attracted the attention of researchers and practicing engineers to manufacture tool electrodes with highly great performance. In this work, an experimental design was conducted to characterize the machining performances and surface integrity of three different composition of copper tungsten (CuW) tool electrode in EDM of D2 hardened steel (58-62 HRC). Machining performances i.e. material removal rate (MRR), tool wear rate (TWR), workpiece surface roughness (Ra) and micro-hardness (MH) were studied for the three different composition of CuW tool electrode made through powder metallurgy (PM) method. Machining variables were peak current and pulse duration, meanwhile machining voltage, depth of cut and duty factor were kept constant. The 65%W electrode is the best choice of CuW electrode on machining D2 hardened steel due to the highest machining rate, reasonable tool wear rate and acceptable surface characteristics. The improvement of MRR is obviously affected by the increment of current intensity. MRR increased as the value of peak current increased. The increment of pulse duration is not essentially improving MRR. There is no clear relation between the alteration of pulse duration and MRR. However, the MRR becomes the optimum at an optimal set of variables which is set at 40A and 400µs. The results of the machining performance can extent the availability of database on EDM machinability and surface characteristics of D2 hardened steel for machinist practices in industrial application of roughing operation. 2013-05 Thesis http://eprints.uthm.edu.my/1899/ http://eprints.uthm.edu.my/1899/1/24p%20FAIZUL%20EZMAT%20ABDUL%20HAMID.pdf text en public http://eprints.uthm.edu.my/1899/2/FAIZUL%20EZMAT%20ABDUL%20HAMID%20COPYRIGHT%20DECLARATION.pdf text en staffonly http://eprints.uthm.edu.my/1899/3/FAIZUL%20EZMAT%20ABDUL%20HAMID%20WATERMARK.pdf text en validuser mphil masters Universiti Tun Hussein Onn Malaysia Fakulti Kejuruteraan Mekanikal dan Pembuatan
institution	Universiti Tun Hussein Onn Malaysia
collection	UTHM Institutional Repository
language	English English English
topic	TJ Mechanical engineering and machinery TJ1125-1345 Machine shops and machine shop practice
spellingShingle	TJ Mechanical engineering and machinery TJ1125-1345 Machine shops and machine shop practice Abdul Hamid, Faizul Ezmat Investigation on different composition of powder metallurgy electrode (Cu-W) in high performance edm (HPEDM) on AISI D2 hardened steel
description	The ideal selection of manufacturing conditions is one of the most important aspects to take into consideration in the majority of manufacturing processes and particularly in processes related to Electrical Discharge Machining (EDM). EDM die sinking machines are used to machine conductive metals of any hardness or difficult to machine with traditional methods. The problem in the capabilities of tool electrodes which are not utilized at the optimum levels of the operating parameters has attracted the attention of researchers and practicing engineers to manufacture tool electrodes with highly great performance. In this work, an experimental design was conducted to characterize the machining performances and surface integrity of three different composition of copper tungsten (CuW) tool electrode in EDM of D2 hardened steel (58-62 HRC). Machining performances i.e. material removal rate (MRR), tool wear rate (TWR), workpiece surface roughness (Ra) and micro-hardness (MH) were studied for the three different composition of CuW tool electrode made through powder metallurgy (PM) method. Machining variables were peak current and pulse duration, meanwhile machining voltage, depth of cut and duty factor were kept constant. The 65%W electrode is the best choice of CuW electrode on machining D2 hardened steel due to the highest machining rate, reasonable tool wear rate and acceptable surface characteristics. The improvement of MRR is obviously affected by the increment of current intensity. MRR increased as the value of peak current increased. The increment of pulse duration is not essentially improving MRR. There is no clear relation between the alteration of pulse duration and MRR. However, the MRR becomes the optimum at an optimal set of variables which is set at 40A and 400µs. The results of the machining performance can extent the availability of database on EDM machinability and surface characteristics of D2 hardened steel for machinist practices in industrial application of roughing operation.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Abdul Hamid, Faizul Ezmat
author_facet	Abdul Hamid, Faizul Ezmat
author_sort	Abdul Hamid, Faizul Ezmat
title	Investigation on different composition of powder metallurgy electrode (Cu-W) in high performance edm (HPEDM) on AISI D2 hardened steel
title_short	Investigation on different composition of powder metallurgy electrode (Cu-W) in high performance edm (HPEDM) on AISI D2 hardened steel
title_full	Investigation on different composition of powder metallurgy electrode (Cu-W) in high performance edm (HPEDM) on AISI D2 hardened steel
title_fullStr	Investigation on different composition of powder metallurgy electrode (Cu-W) in high performance edm (HPEDM) on AISI D2 hardened steel
title_full_unstemmed	Investigation on different composition of powder metallurgy electrode (Cu-W) in high performance edm (HPEDM) on AISI D2 hardened steel
title_sort	investigation on different composition of powder metallurgy electrode (cu-w) in high performance edm (hpedm) on aisi d2 hardened steel
granting_institution	Universiti Tun Hussein Onn Malaysia
granting_department	Fakulti Kejuruteraan Mekanikal dan Pembuatan
publishDate	2013
url	http://eprints.uthm.edu.my/1899/1/24p%20FAIZUL%20EZMAT%20ABDUL%20HAMID.pdf http://eprints.uthm.edu.my/1899/2/FAIZUL%20EZMAT%20ABDUL%20HAMID%20COPYRIGHT%20DECLARATION.pdf http://eprints.uthm.edu.my/1899/3/FAIZUL%20EZMAT%20ABDUL%20HAMID%20WATERMARK.pdf
_version_	1747830877493133312

Investigation on different composition of powder metallurgy electrode (Cu-W) in high performance edm (HPEDM) on AISI D2 hardened steel

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