Abstract
This article presents the investigations on micro-geometry of fine pitch miniature spur gears manufactured by wire electrical discharge machining (WEDM). Effects of voltage, pulse-on time, pulse-off time, wire feed rate and cutting speed on total profile and accumulated pitch errors were studied using one-factor-at-a-time approach. The miniature gears had a module of 0.7 mm, outside diameter 9.8 mm, face width 4.9 mm, and were made of brass. The best quality manufactured gear had DIN quality number of 6 and 8, respectively, for pitch and profile with average and maximum surface roughness values of 1 µm and 6.4 µm, respectively, establishing WEDM as a superior process for miniature gear manufacturing. It was observed that wire-lag and irregular shaped craters produced by high discharge energy parameters are responsible for micro-geometry errors of miniature gears manufactured by WEDM. Use of low voltage and pulse-on time, avoiding high pulse-off time, maximum values of wire feed rate and cutting speed are recommended to manufacture the high quality miniature gears by efficient and stable WEDM. This study found 5–15 V for voltage, 0.6–1.0 µs for pulse-on time, 90–170 µs for pulse-off time, 9–15 m/min for wire feed rate, and 100% cutting speed as the optimum settings for further investigations.
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