Evaluation of Electrical Discharge Machining parameters on energy saving and machining characteristic enhancement of biodegradable AZ31 Magnesium Alloy

Norizwan Juraimi

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Type :	thesis
Subject :	TJ Mechanical engineering and machinery
Main Author :	Norizwan Juraimi
Title :	Evaluation of Electrical Discharge Machining parameters on energy saving and machining characteristic enhancement of biodegradable AZ31 Magnesium Alloy
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Place of Production :	Tanjong Malim
Publisher :	Fakulti Teknikal dan Vokasional
Year of Publication :	2024
Corporate Name :	Perpustakaan Tuanku Bainun
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Abstract : Perpustakaan Tuanku Bainun

Magnesium alloys have been widely used in biodegradable applications due to their propensity for corroding within the human body and their initial mechanical properties. However, recent research has shown that the increased rate of magnesium deterioration inside the human body causes structural stability of the implant to be disturbed and lost quickly. Electrical discharge machining (EDM) die sinking is a machining technique used to produce complex forms with high tolerance in magnesium alloy, focusing on the relationship between process parameters and machining effect. The research aims to investigate the effect of EDM process parameters on surface roughness, material removal rate (MRR), and energy consumption to optimize and validate the machining parameter prone to energy saving and the best machining characteristic. The experiments were optimized using a design of experiment approach with a full factorial design and response surface methodology. The relationship models between the controlled design parameters of pulse-on-time, pulse-off-time, and peak current and the responses of material removal rate were validated through confirmation runs, and the average percentage errors between experimental data and predicted values for each response were within the acceptable range (less than or equal to 10%). Pulse-on-time was the prominent factor that affects the material removal rate and surface roughness, while pulse-off-time appeared to be the most influential parameter for energy consumption. Nonetheless, peak current appeared to be insignificant among all factors in this study as it depends on the level of pulse-on-time applied. Higher pulse-on-time caused larger surface roughness. Therefore, surface integrity of the workpiece depends on the level of pulse-on-time applied. The optimum setting parameter combination to achieve optimum response MRR (0.041 g/min), surface roughness (3.191 μm) and energy consumption (0.702 J/g) was high peak current (14.00 A), low pulse-on-time (2.00 μs), and low pulse off time (10.00 μs).

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