Spark erosion machining of miniature gears: a critical review

Gupta, Kapil; Jain, Neelesh Kumar; Laubscher, R. F.

doi:10.1007/s00170-015-7130-2

Cited by 21 publications

(10 citation statements)

References 31 publications

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“…Electric discharge machining (EDM), also known as spark erosion machining, is a thermal type advanced machining process where the material removal takes place by melting and vaporization caused due to series of repeated electrical discharges occur between the two electrodes cathode (tool) and anode (workpiece) when a suitable dielectric fluid is supplied in the inter-electrode gap (see Figure 3). 15 Joseph Priestly noticed the phenomenon of material erosion by electric spark in 1878, and in 1930 it was started to use this concept for machining purposes. A Russian scientist Lazarenko firstly used electric sparks for the controlled machining operations.…”

Section: Nonconventional Machining and Sustainable Productionmentioning

confidence: 99%

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Developments in nonconventional machining for sustainable production: A state-of-the-art review

Gupta

2018

Proceedings of the Institution of Mechanical Engineers, Part C:

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Nonconventional or advanced machining processes such as electric discharge machining, electrochemical machining, abrasive water jet machining, and laser beam machining have been widely used as a viable alternate to the conventional processes to manufacture high-quality engineered parts having certain typical features. In spite of their special features, wider acceptance, and use, they suffer from certain inherent limitations with regard to sustainability such as high consumption of energy and resources; generation of toxic liquid, gases, and solid wastes; risk for health and safety; air pollution; generation of waste and its disposal problems; and workpiece contamination and thermal damage to the parts being produced. It is found that these factors all adversely affect the environment to a certain extent. Innovative sustainable techniques such as dry, near-dry, and green electric discharge machining; green and hybrid electrochemical machining; ice-jet machining; and eco- and underwater laser beam machining, etc. have been developed to address sustainability challenges and greatly benefited with improvements in quality, productivity, and sustainability. This review article first introduces four major nonconventional machining processes, discusses their inherent sustainability issues and challenges, and presents state-of-the-art review of the work conducted using sustainable innovative techniques and strategies with an aim to encourage academics, researchers, and engineers for research and developments in order to establish the field further. The literature review offered in this article is based on over 80 articles published from 1975 to 2017. Finally, the article ends up with concluding remarks and recommending possible avenues to stimulate future research.

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Section: Nonconventional Machining and Sustainable Productionmentioning

confidence: 99%

“…EDM has been a first choice of manufacturers for near-net shape manufacturing of dies and molds; micro parts and features; machining of superalloys, bio-materials, and other DTM materials for automobiles, aerospace, nuclear, and biomedical applications. 15,16…”

Section: Nonconventional Machining and Sustainable Productionmentioning

confidence: 99%

Developments in nonconventional machining for sustainable production: A state-of-the-art review

Gupta

2018

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…Miniature gears have found extensive applications in microelectromechanical systems, miniature motors and pumps, domestic appliances, bio-medical instrument, business machines, and various other devices. [1][2][3] The fine-pitched miniature gears made of brass are generally used for motion transmission and subjected to run at very high speed even up to 50,000 r/min. Low running noise, accuracy in motion transmission, low wear rate, high fatigue life, and tribological fitness are the important characteristics signifying high functional performance and long service life of gears.…”

Section: Introduction and Background Workmentioning

confidence: 99%

“…Therefore, the gear should have high geometric accuracy, precision surface finish, and good surface integrity aspects. [2][3][4] The manufacturing processes play an important role in attaining the aforementioned parameters with regard to the fitness of gears.…”

Section: Introduction and Background Workmentioning

confidence: 99%

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Investigations on surface roughness and tribology of miniature brass gears manufactured by abrasive water jet machining

Phokane

Gupta

2017

Proceedings of the Institution of Mechanical Engineers, Part C:

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Surface roughness parameters are important indicators for determining the operating performance, tribology behavior, wear and tear characteristics, and service life of engineered parts including gears. This article presents the investigation on surface roughness, and tribology and wear aspects of miniature brass gears manufactured by abrasive water jet machining. Experiments have been conducted based on Taguchi's robust design technique with L9 orthogonal array to machine external spur-type miniature gears of brass having 8.4 mm pitch diameter, 12 teeth, and 5 mm thickness. The effect of three important process parameters namely water jet pressure, abrasive mass flow rate, and stand-off distance on mean roughness depth of miniature gears are analyzed. Surface roughness is found to decrease with the increase in the water jet pressure and abrasive mass flow rate, and increases with the increase in the stand-off distance. Particle swarm optimization technique has been used for parametric optimization to minimize the surface roughness of miniature gears. Confirmation experiment conducted at optimized abrasive water jet machining parameters resulted in superfine surface finish with mean roughness depth value of 4.1 µm superior than the finish obtained by other advanced processes for brass gears. The investigated values of bearing area characteristics, skewness, kurtosis, and friction coefficient confirm the tribological fitness of the miniature brass gear machined at optimum abrasive water jet machining parameters.

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