Exploring WSEM process for manufacturing meso helical and bevel gears

Abstract

This paper presents an experimental investigation with objective to explore and establish WSEM (wire spark-erosion machining) process as a technically superior alternative for manufacturing the best quality and closed to net-shape meso helical gear (MHG) and meso bevel gear (MBG) made of stainless steel (SS 304). Effect of variable WSEM parameters namely servo voltage 'SV', pulse-on-time 'Ton', peak current 'IP', pulse-off time 'Toff', feed rate of wire 'WF', wire tension 'WT', dielectric flow rate 'WP' and percentage cutting speed 'CS' on gear cutting rate (GCR) and average surface roughness (Ra) are studied. The experiments were planned and designed according to one-variable-at-time approach of 'Design of Experiments' to determine the variation in gear cutting rate and average surface roughness with WSEM process parameters. It was observed that servo voltage, pulse-on-time and peak current significantly affect the GCR and Ra. Gear quality standard up to DIN quality number 7 for error in single and error in total pitch of MBG; and DIN quality number 7 and 6 for error in total profile and error in total pitch respectively of MHG were achieved by WSEM process. This study explores capabilities and superiority of WSEM to manufacture closed to net-shape MHG and MBG. © 2018 Elsevier Ltd. All rights reserved.