Experimental investigation on the surface quality of WEDM machined 20MnCr5 steel for gear application

Abstract

The current study investigates experimentally the Wire-cut Electrical Discharge Machining (WEDM) of 20MnCr5 steel. WEDM is used to manufacture gears, shafts, spindles, camshafts, and other mechanical controlling components. In order to analyse the three performance parameters such as profile error, material removal rate (MRR), and surface roughness (SR), five WEDM parameters were employed in the trials: wire feed (Wf), wire tension (Wt), servo voltage (SV), discharge arc-off time (Toff), and arc-on time (Ton). When compared to the effects of arc on time and servo voltage on MRR, wire feed rate and tension are less important. Higher arc-on time and servo voltage have produced more profile inaccuracy. Decreased wire tension values cause the surface roughness to be more significant and result in lower roughness. As the voltage increases, an uneven surface with a large globule and a deep crater forms on the machined surface. The recast layer becomes thicker at a higher arc on time and servo voltage.

Effect of carburizing time treatment on microstructure and mechanical properties of low alloy gear steels

“…The relentless pursuit of technological advancements across various industries has driven a constant demand for materials with exceptional mechanical properties. Low-alloy steels, with their cost-effectiveness and desirable mechanical properties, have become a mainstay in critical components like gears, shafts, bearings, and tools [1,2]. However, their inherent limitations, such as low hardness, limited wear resistance, and susceptibility to fatigue, restrict their suitability for demanding applications where durability and reliability are paramount [3,4].…”