Optimization of Single Pitch Error and MRR in a WEDM Gear Cutting Process

Gears are the key elements to the manufacturing processes. Gears having teeth or wheels mesh together with other gears to transmit torque. Accurate motion transfer and minimum running noise are the two most important features for these gears which depend on the amount of errors, i.e. the errors present in the pitch of the gears. Gears can be manufactured by different manufacturing processes such as shaping, forming, hobbing, milling and broaching. Gears are one of the crucial components of the highly accurate miniaturized devices such as pumps and motors, electronics, business machines, home appliances, automotive parts, measuring instruments, timing devices, MEMS, etc. It is also used in the scientific, industrial and domestics areas. Gear cutting by WEDM finds its application in many industrial areas of aeronautical and electrical industries that requires precise finishing and appropriate accuracy. Geared devices can change the torque, speed and direction of the power source. Copper, bronze, brass, stainless steel and aluminium are the most frequently used materials for these gears. In the present investigation, miniature copper gears of 2 mm thickness are cut by WEDM and the machine parameters are optimized.