Investigation of Involute Profile Error on Spur Gear Processed using Wire EDM

Abstract

Demand on high accuracy product are getting raised recently. Wire Electrical Discharge Machining (EDM) is one of non-conventional machining who can produce high accuracy product with two axis. By using sparks from electrical energy to erode material in conductive fluid, called electrode fluid. A spur gear with JIS B 1701:1973 standard has specific criteria, including dimension and mechanical tolerance. DIN 1.2378 is a medium carbon steel which is common to use as a gear in automotive industry. This martial is like the ordinary one, but with an extra nickel. The aim of this research is to observe how far effect Wire EDM parameter process such as pulse on time, open voltage, pulse current and wire tension affected on involute profile error of spur gear shape with Taguchi matrix orthogonal L18 methods as experimental design. From research we concluded that the most involute profile error is a minus profile, it means involute curve on actual gear smaller than ideal involute curve. The smallest dimensional distortion involute profile error is 79μm and the highest 125μm. Process parameter pulse on time, open voltage, and pulse current has directly proportional to involute profile error, while wire tension has inversely proportional to involute profile error.

Prediction of Tooth Profile Deviation for WEDM Rigid Gears Based on ISSA-LSSVM

“…Peng et al [7] analyzed the tooth profile deviation in the hobbing forming process base on the theory of gear meshing, and adjusted the hobbing process parameters for the deviation size. Yusron et al [8] performed a study analyzing how wire-cutting parameters, including pulse width, open circuit voltage, wire tension, and pulse current, affect the deviation of the straight-toothed cylindrical gear tooth profile through orthogonal experiments. Vishal et al [9] found that adjusting hobbing parameters can greatly impact the microgeometry deviation and average deviation of gears.…”