Investigations on surface quality of WEDM-manufactured meso bevel and helical gears

Chaubey, Sujeet Kumar; Jain, Neelesh Kumar

doi:10.1080/10426914.2017.1415440

Cited by 23 publications

(5 citation statements)

References 14 publications

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“…Pulse off time, voltage, wire feed, current and wire tension. In this research observed that pulse width and current are affect the surface roughness and cutting speed [11]. The superior mechanical property materials Inconel 718 machined by WEDM.…”

Section: B Wire Electrical Discharge Machinementioning

confidence: 76%

A Research on Machinability of Bio Implant by Electric Discharge Machining Process

2019

IJRTE

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Increasing demand in industries to manufacturing the complex geometric shape and hard materials parts is extremely difficult to cut by the conventional machining process. The non-conventional machine is used for the manufacturing of 3D complex and geometry shapes without compromise the required specification. Electro discharge machining (EDM) is a non-traditional machining process, which is very widely used in recent days. EDM process is electrical and thermal energy generated between work piece and an electrode. The major applications are dies, moulds, aerospace parts, automotive industry, and surgical components. The human implant materials like Stainless Steel, Titanium and Co-Cr based alloys are widely used in biomedical fields. This paper shows that fundamental studies on electrical discharge machining (EDM), Wire electrical discharge machining (WEDM) and human implant materials with newly developed advance technologies in the current scenario.

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Section: B Wire Electrical Discharge Machinementioning

confidence: 76%

A Research on Machinability of Bio Implant by Electric Discharge Machining Process

2019

IJRTE

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“…Surface roughness has several parameters, but average surface roughness ‘ R a ’ and the total height of roughness profile ‘ Rt ’, also known as maximum surface roughness, are the two most important parameters referred to in the manufacturing of engineered microparts. These parameters significantly affect the service life, noiseless and smooth operating performance of a gear [ 14 , 15 ].…”

Section: Experimentationmentioning

confidence: 99%

“…It has been used for the manufacturing of microparts including gears because it is a material saving process, requires minimum attention during manufacturing, and is easy to operate and handle [ 9 , 10 ]. Previous work on miniature gear manufacturing by WTEM is limited to brass and stainless-steel materials [ 11 , 12 , 13 , 14 ]. To the best knowledge of the authors, attempts on manufacturing lightweight aluminium gears with bore and hub by WTEM process are scarce and a detailed investigation is required to be conducted to complement miniaturization.…”

Section: Introductionmentioning

confidence: 99%

A Comprehensive Investigation on Development of Lightweight Aluminium Miniature Gears by Thermoelectric Erosion Machining Process

2021

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Nowadays, size, weight, and durability are crucial factors in product development that draw the attention of many researchers and engineers towards research and innovation in the micromanufacturing area. This paper reports on the development of a lightweight aluminium gear of miniature size with a bore and hub using wire-assisted thermoelectric erosion machining (WTEM). The external spur gear was cut from 7075 aluminium alloy round stepped gear blank by WTEM using 0.25 mm brass wire. Further, the miniature gear was tested for various manufacturing quality parameters such as microgeometry, surface roughness, and microstructure, along with evaluating process productivity in terms of volumetric gear cutting speed To understand the mechanism of development of aluminium miniature gear, an investigation on the influence of WTEM parameters namely servo-voltage, pulse-on time, pulse-off time, and wire speed on surface roughness was conducted. A total of 18 gears were fabricated following Taguchi L9 (34) orthogonal array approach of design of experiments considering the randomization and replication. A typical average surface roughness value of 1.58 μm and manufacturing quality of DIN standard number 7 based on gear microgeometry were successfully achieved. Microscopic investigation revealed uniform and accurate tooth profiles, flank surfaces free from burrs and contaminants, and uniform microstructure that confirm the good performance characteristics of the developed lightweight miniature gear of aluminium. This investigation will add new results in the field as regards the development of lightweight microparts.

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“…Poor gear quality (DIN 9-12), sharp edge definition, burr, microcracks, tool marks, applicable for specific types of gears and materials, requirement of appropriate finishing and hardening processes are some limitations of these processes. These inherent limitations of these manufacturing process and demands of high quality meso-sized gears at reasonable price in global market motivate the researchers to develop and explore another alternative process to manufacture high quality of meso-sized gears with higher productivity and minimum manufacturing cost [3,4]. Wire spark-erosion machining (WSEM) is emerging advanced machining process to manufacture high quality of meso-sized cylindrical (i.e.…”

Section: Introductionmentioning

confidence: 99%

“…Therefore, selection of optimum WSEM parameters plays important role to manufacture high quality MHG and MBG with higher productivity and minimum manufacturing cost. Its offers several advantages to manufacture meso-sized cylindrical and conical gears (MCCG): (i) ability to manufacture MCCG from any electrically conductive materials of any hardness and thickness; (ii) manufacture different size and shape of gears from same gear plate without changing tool electrode (very thin brass wire) thus minimize total setting time; (iii) higher dimensional accuracy with smooth and burr-free flank surfaces; (iv) achieved gear quality of MCCG up to DIN 6-7 along with higher wear resistance on flank surfaces without using any subsequent finishing and hardening process; and (v) unattended manufacturing of MCCG [2,3].…”

Section: Introductionmentioning

confidence: 99%

On Productivity of WSEM Process for Manufacturing Meso-Sized Helical and Bevel Gears

Chaubey

Jain

2018

IOP Conf. Ser.: Mater. Sci. Eng.

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Corresponding author: sujeetiiti@gmail.comAbstract. This paper reports on productivity of wire spark-erosion-machining (WSEM) process for manufacturing meso-sized helical gear (MHG) and meso-sized bevel gear (MBG). Productivity of WSEM process is measured by volumetric gear cutting rate (VGCR). Variation in VGCR with four WSEM parameters such as servo voltage 'S V ' pulse-on time 'T on ', pulse-off time 'T off ', and feed rate of wire 'W F ' is also studied. Box-Behnken design approach of Response Surface Methodology (RSM) was used to design and conduct 29 experimental runs with replicates twice for analysis of VGCR. Analysis of variance (ANOVA) was used to determine the significant parameters and their interactions. It was observed that all considered WSEM parameters are significant and considerably affect VGCR. Desirability function analysis was used to find the optimum WSEM parameters so as to enhance the productivity of WSEM process to manufacture the better quality of MHG and MBG. Confirmation experiments were performed to validate the optimized values of VGCR corresponding to MHG and MBG and achieved much closer to it. Scanning electron micrographs (SEM) of MHG and MBG revealed uniform and burr-free tooth profile, bore and smoother cracks-free flank surfaces.

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Investigations on surface quality of WEDM-manufactured meso bevel and helical gears

Cited by 23 publications

References 14 publications

A Research on Machinability of Bio Implant by Electric Discharge Machining Process

A Research on Machinability of Bio Implant by Electric Discharge Machining Process

A Comprehensive Investigation on Development of Lightweight Aluminium Miniature Gears by Thermoelectric Erosion Machining Process

On Productivity of WSEM Process for Manufacturing Meso-Sized Helical and Bevel Gears

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