The Performance of Brass Electrode on Material Removal for Aluminium Composite in EDM Die-Sinking


Article Preview

This paper investigates the performance of brass electrode on the removal of aluminium alloys LM6 (Al-Sil2) in an electrical discharge machining (EDM) die-sinking. The machining parameters such as pulse-on time, pulse-off time and peak current were selected to find the responses on the material characteristics such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Brass with diameter of 10mm was chosen as an electrode. Orthogonal array of Taguchi method was used to develop experimental matrix and to optimize the MRR, EWR and Ra. It is found that the current is the most significantly affected the MRR, EWR and Ra while pulse on time, pulse off time and voltage are less significant factor that affected the responses. Percentage optimum value of MRR increases to 3.99%, however EWR and Ra reduce to 3.10% and 2.48% respectively. Thus, it shows that brass having capability to cut aluminium alloys LM6.



Edited by:

Amir Khalid, Bukhari Manshoor, Erween Abdul Rahim, Waluyo Adi Siswanto and Kamil Abdullah




A. A. Mohd et al., "The Performance of Brass Electrode on Material Removal for Aluminium Composite in EDM Die-Sinking", Applied Mechanics and Materials, Vol. 660, pp. 43-47, 2014

Online since:

October 2014




* - Corresponding Author

[1] R. Kern, Sinker electrode material selection, EDM Today, July/August 2008 issue.

[2] T.R. Vijayaram, A. Kamely, E Sachlan, Effect of Lead Addition on LM6 Alloy Castings, J. Mech. Eng. Tech. 2 (2010) 66-75.

[3] A.B.M. Hadzley, A.S. Sarah, A.A.R. Izamshah, M.A.M. Amran, K.M. Shahir, S.M. Amri, N. Fatin, M. Raffi, Evaluation on the surface integrity when machining LM6 aluminium metal matrix composites using coated and uncoated carbide cutting tools, Appl. Mech. Mater. 465 (2014).


[4] M.A. Amran, L. Suraya, I.K. Halida, H.N.I. Syahriah, M.R. Muhamad, B. Manshoor, M.A. Lajis, R. Izamshah, M. Hadzley, R.S. Taufik, The effect of EDM die-sinking parameters on materials characteristics for aluminium composite using tungsten copper electrode, Appl. Mech. Mater. 465 (2014).


[5] M.A. Amran, M. Samsul, N.I.S. Hussein, M. Rizal, R. Izamshah, M. Hadzley, M.S. Kasim, M.A. Sulaiman and S. Sivarao, The effect of EDM die-sinking parameters on material removal rate of beryllium copper using full factorial method, Middle-East J. Sci. Res. 16 (2013).

[6] M.A. Amran, L. Suraya, N.J.S. Atiqah, H.N.I. Syahriah, M.R. Muhamad, B. Manshoor, M.A. Lajis, R. Izamshah, M. Hadzley, R.S. Taufik, The Effect of EDM Die-sinking Parameters on Material Characteristics for Aluminium Composite, submitted to Applied Mechanics Materials (ISSN: 1660-9336) in press.


[7] R. Izamshah, M.Y. Yuhazri, M. Hadzley, M.A. Amran, S. Sivarao, Effects of end mill helix angle on accuracy for machining thin-rib aerospace component, Appl. Mech. Mater. 315 (2013) 773-777.


[8] S.H. Lee, X.P. Li, Study of the effect of machining parameters on the machining characteristic in electrical discharge machining of tungsten carbide, J. Mater. Pro. Tech. (2001) 344-358.


[9] M. Lajis, H. Radzi, A.A. Amin, The implementation of Taguchi method on EDM process of tungsten carbide, Eur. J. Sci. Res. 26 (2009) 609-617.

[10] R. Karthikeyan, P.R.L. Narayanan, R.S. Naagarazan, Mathematical modelling for electrical discharge machining of Aluminium-silicon carbide particulate composite, J. Mater. Pro. J. 87 (1997) 59-63.


[11] P.J. Liew, J. Yan, T. Kuriyagawa, Fabrication of deep micro-holes in reaction-bonded SiC by ultrasonic cavitation assisted micro-EDM, Inter. J. Auto. Tech. 7 (2014) 621-629.


[12] K.L. Senthil Kumar, R. Sivasubramaniam, K. Kalaiselvan, Selection of optimum parameters in non conventional machining of metal matrix composite. Portugaliae Electrochimica Acta. 27 (2009) 477-486.


[13] A.A. Khan, Electrode wear and material removal rate during edm of aluminium and mild steel using copper and brass electrodes. Int. J. Adv. Manuf. Tech. 39 (2008) 482-487.


[14] A. Pandey, S. Singh, Current research trends in variants of electrical discharge machining. J. Sci. Tech. 2 (2010) 2172-2191.