Investigations on microgeometry of meso bevel and meso helical gears manufactured by WEDM process

Chaubey, Sujeet Kumar; Jain, Neelesh Kumar

doi:10.1007/s00170-017-0884-y

Cited by 10 publications

(8 citation statements)

References 10 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Using the powder extrusion process, Kim and Ko 12 made meso helical gears with powder Zn–22 wt% Al with an outside diameter of 2.55–4.348 mm, a module of 0.2–0.3 mm, a tooth number of 12 and a helix angle of 15°. By using the micro wire cut electrical discharge machining(μ-WEDM) process, Chaubey and Jain 13 made meso helical and bevel gears with an outer diameter of8–10 mm and quality of DIN6–7. The review of Chaubey and Jain 1 provides a detailed summary of the manufacturing of meso and micro cylindrical gears and reaches the following conclusion: Most of the existing technologies yield poor quality meso and micro gears, reaching a quality standard of DIN9–12.…”

Section: Introductionmentioning

confidence: 99%

Two-step method of nanosecond pulse laser ablation manufacturing of miniature bevel line gears

Chen

Xie

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

Miniature gears have important research value and application prospects in micro-scale machinery. The existing manufacturing methods for miniature gears produce spur gears on the micron scale and spur, helical and bevel gears on the millimetre scale. However, there is no mature process for gears on the micron scale for angular transmissions, such as bevel gears. This article reports for the first time the micro-machining of a miniature bevel gear with an external size of 1–2 mm based on a novel gear structure: the bevel line gear. First, a novel manufacturing method, namely the two-step method of nanosecond pulse laser ablation (NSPLA), is proposed. Then, a sample of a miniature bevel line gear is fabricated from 6061 aluminium alloy with a top angle of 90°, external diameter of 1375 μm, tooth number of 3 and average tooth width of 20 μm. Finally, the accuracy of the sample is studied to confirm the practicability of the proposed method.

show abstract

Section: Introductionmentioning

confidence: 99%

Two-step method of nanosecond pulse laser ablation manufacturing of miniature bevel line gears

Chen

Xie

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…In the WEDM process, a brass copper wire is fed between two guides in the presence of a dielectric medium, normally deionized water [7]. The wire follows a programmed NC path while generating electrical discharges that remove material from the work-piece, which must be electrically conductive.…”

Section: Introductionmentioning

confidence: 99%

Unsupervised Machine Learning for Advanced Tolerance Monitoring of Wire Electrical Discharge Machining of Disc Turbine Fir-Tree Slots

Wang

Sánchez

Ayesta

et al. 2018

Sensors

View full text Add to dashboard Cite

Manufacturing more efficient low pressure turbines has become a topic of primary importance for aerospace companies. Specifically, wire electrical discharge machining of disc turbine fir-tree slots has attracted increasing interest in recent years. However, important issues must be still addressed for optimum application of the WEDM process for fir-tree slot production. The current work presents a novel approach for tolerance monitoring based on unsupervised machine learning methods using distribution of ionization time as a variable. The need for time-consuming experiments to set-up threshold values of the monitoring signal is avoided by using K-means and hierarchical clustering. The developments have been tested in the WEDM of a generic fir-tree slot under industrial conditions. Results show that 100% of the zones classified into Clusters 1 and 2 are related to short-circuit situations. Further, 100% of the zones classified in Clusters 3 and 5 lie within the tolerance band of ±15 μm. Finally, the 9 regions classified in Cluster 4 correspond to situations in which the wire is moving too far away from the part surface. These results are strongly in accord with tolerance distribution as measured by a coordinate measuring machine.

show abstract

“…tip diameter ranging from 1 to 10 mm) are core constituents of these devices and commonly used for actuating and driving purposes. Meso-sized motors, pumps, gearboxes and actuators are some typical applications of these gears which are extensively used in chemical industries, dental and surgical instruments, precision instruments, prototype models, and domestic appliances [1,2]. These gears are become more popular due to their light weight and small volume, stable superior performance, longer service life, minimum materials and manufacturing cost.…”

Section: Introductionmentioning

confidence: 99%

“…Operating performance and service life of these gears are governed by its overall quality (i.e. aspects of gear quality and surface quality) [2]. Manufacturing processes and materials considerably affect the overall quality, manufacturing time and cost of mesosized gears.…”

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%

See 1 more Smart Citation

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

Chaubey

Jain

2018

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

View full text Add to dashboard Cite

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.

show abstract

Investigations on microgeometry of meso bevel and meso helical gears manufactured by WEDM process

Cited by 10 publications

References 10 publications

Two-step method of nanosecond pulse laser ablation manufacturing of miniature bevel line gears

Two-step method of nanosecond pulse laser ablation manufacturing of miniature bevel line gears

Unsupervised Machine Learning for Advanced Tolerance Monitoring of Wire Electrical Discharge Machining of Disc Turbine Fir-Tree Slots

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

Contact Info

Product

Resources

About