Comparison of Duplex Stainless Steel (2205) Spur Gears Cut by Wire Electrodischarge Machining (WEDM) and Hobbing Under Dry Condition

Abstract

The present work deals with the influence of machining process on surface roughness and tool wear performances of spur gears under dry conditions, that is without any lubrication. Spur gears profiles are mathematically modelled and generated in CAD software. Using super-duplex stainless steel, spur gears has fabricated using hobbing and wire cut EDM processes. An experimental rig has developed to test the gear under dry operation conditions and variation of teeth wear and roughness has measured under dry conditions (without lubricants). Teeth of wire cut EDM gears are stronger compared to hobbed gear for same dimensions. Teeth surface roughness of the WEDM gears is much higher compared to hobbed gears. Initially (at lower RPM), wear rate of the WEDM gears teeth is little higher compared to hobbed gears because of higher surface roughness of WEDM gears.