Proportional Analysis and Microstructural Characterization of Threading Dies Manufactured Using Conventional and EDM Machining Methods

This experimental study investigates the effects of conventional and non-conventional (Electrical Discharge Machining, EDM) techniques on the performance of threading dies fabricated from H13 die steel. The research focuses on variations in material properties, operational efficiency, and failure mechanisms. Results indicate that conventional machining significantly increases die hardness, leading to higher mechanical stress and premature failure. In contrast, EDM maintains structural integrity with minimal hardness variation. Microstructural analysis confirms superior grain structure stability in EDM-processed dies. Performance testing showed that conventional threading dies failed after threading 16 inches of mild steel rods, while EDM-fabricated dies successfully threaded up to 20 inches. These findings underscore the detrimental effect of mechanically induced stress in conventional techniques and highlight the superior durability and dimensional precision achievable through non-conventional machining methods.