WEDM Manufacturing Method for Noncircular Gears, Using CAD/CAM Software

García-Hernández, César; Gella-Marín, Rafael; Talón, José Luís Huertas; Efkolidis, Nikolaos; Kyratsis, Panagiotis

doi:10.5545/sv-jme.2015.2994

Cited by 14 publications

(7 citation statements)

References 14 publications

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“…A number of studies prove that the APIs can be useful to the manufacturing-related area of research also. García-Hernández et al [4] proposed a method to manufacture elliptical and oval gears using Wire Electro-Discharge Machining (WEDM). Authors presented the mathematical models and simulations based on CAD and CAM systems.…”

Section: Introductionmentioning

confidence: 99%

CAD-Based Automated Design of FEA-Ready Cutting Tools

Tzotzis

García-Hernández

Talón

et al. 2020

JMMP

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The resources of modern Finite Element Analysis (FEA) software provide engineers with powerful mechanisms that can be used to investigate numerous machining processes with satisfying results. Nevertheless, the success of a simulation, especially in three dimensions, relies heavily on the accuracy of the cutting tool models that are implemented in the analyses. With this in mind, the present paper presents an application developed via Computer-Aided Design (CAD) programming that enables the automated design of accurate cutting tool models that can be used in 3D turning simulations. The presented application was developed with the aid of the programming resources of a commercially available CAD system. Moreover, the parametric design methodology was employed in order to design the tools according to the appropriate standards. Concluding, a sample tool model was tested by performing a number of machining simulations based on typical cutting parameters. The yielded results were then compared to experimental values of the generated machining force components for validation. The findings of the study prove the functionality of the tool models since a high level of agreement occurred between the acquired numerical results and the experimental ones.

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Section: Introductionmentioning

confidence: 99%

CAD-Based Automated Design of FEA-Ready Cutting Tools

Tzotzis

García-Hernández

Talón

et al. 2020

JMMP

Self Cite

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“…Some advantages of WEDM processes are that they allow machining different conductive materials regardless of their hardness [9], for example, titanium alloys used in biomedical applications [10], and that it is appropriate for delicate or fragile materials, because it eliminates the mechanical stresses that are present in traditional machining processes [11]. Besides, complex shapes and thin-walled parts can be obtained, such as noncircular gears, including elliptical and oval gears [12] or inclined surfaces that are used in tooling that requires draft angle [13]. Moreover, WEDM avoids the need to manufacture the pre-shaped electrodes that are necessary for sink electrical discharge machining (SEDM) [14].…”

Section: Introductionmentioning

confidence: 99%

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Buj-Corral

Zayas-Figueras

Montaña-Faiget

2020

Metals

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Cam-follower mechanisms are usually employed in different machines, like combustion engines, sewing machines, machine tools, etc. In the present paper, the option to manufacture cams utilizing wire electrical discharge machining (WEDM) has been considered. For this, surface roughness and shape error of cam profiles manufactured by the processes of milling and wire electrical discharge machining (WEDM) are presented. The methodology used covers different stages: design, prototyping, manufacturing, and measurement of the cams. As a reference, a cam-follower mechanism from a motorcycle internal combustion engine has been used. A reverse engineering process has been performed to determine the geometrical parameters of the mechanism, which are used for the synthesis of the profile of the cam and its subsequent design. The manufacturing process of the cams has been assisted by CAD-CAM (Computer Assisted Drawing-Computer Assisted Manufacturing) software. Using fused filament fabrication (FFF), a physical prototype of the cam has been manufactured, in order to validate the goodness of the design. Finally, the roughness and shape parameters have been measured on the contour surface of the cams. The arithmetical mean roughness Ra value of the milled cam was 0.269 μm, below the requirement of 0.4 μm, and shape error was 18 μm, below 50 μm. Shape error of the WEDM cam of 48 μm meets the requirements for cams. However, the Ra value of 1.212 μm, exceeded the limit. For this reason, a finish operation is recommended in this case. Some advantages of WEDM cams over milled cams are that different conductive materials can be employed, more complex shapes can be obtained, and that, in rough operations, the amount of material to be removed in subsequent operations is considerably reduced.

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“…The mathematical model of the tooth profile of non-circular gears 2 can be adopted in this article. However, the existing literature regards the tooth crest curve and tooth root curve as non-circular curves similar to the pitch curve 22 , which will cause non-negligible design error of tooth height and contact ratio error accordingly, leading to the interference of conjugate pair to be unable to drive. As shown in Fig.…”

Section: Methodsmentioning

confidence: 99%

Design of piecewise deformed elliptical gear with closed pitch curve and its conjugate pair

Liu

et al. 2022

Sci Rep

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The family of elliptical gears with closed pitch curves includes elliptical gears and deformed elliptical gears. Elliptical gears are not only the most widely used non-circular gears but also the research hotspot in the field of non-uniform transmission. However, adjusting the shape of its pitch curve is difficult, which seriously restricts its popularization. This article proposes a piecewise deformed elliptical gear with a closed pitch curve, which realizes the unity of all kinds of elliptical gears in the mathematical model, makes the shape of the pitch curve and gear ratio easier to adjust, and expands the connotation and application scope of the family of elliptical gears. Moreover, the design approach of transmission with piecewise deformed elliptical gear was studied, and the inspection method of transmission performance was provided. The internal relationship between piecewise deformed elliptical gears and the family of elliptical gears was then analyzed. Finally, the method of computer-aided design (CAD) system developed was also provided. Additionally, a case was provided to verify the above theories. The designed conjugate pair can realize a correct meshing and adjust the gear ratio more flexibly, laying a theoretical foundation to expand the application field of non-uniform transmission.

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WEDM Manufacturing Method for Noncircular Gears, Using CAD/CAM Software

Cited by 14 publications

References 14 publications

CAD-Based Automated Design of FEA-Ready Cutting Tools

CAD-Based Automated Design of FEA-Ready Cutting Tools

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Design of piecewise deformed elliptical gear with closed pitch curve and its conjugate pair

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