Wear Behaviour of Duplex Stainless Steel Spur Gear Produced by CNC Wire Electro-discharge Machining Under Wet Lubrication—An Experimental Approach

Abstract

The present work deals with the influence of machining process on surface roughness and teeth wear performances of spur gears under wet condition (with lubrication). Spur gear profiles are mathematically modelled and generated in CAD software. Using super-duplex stainless steel, spur gears have fabricated using hobbing and wire-cut EDM processes. An experimental rig has developed to test the gear under various operating conditions, and variation of gear teeth wear and roughness has measured under wet lubrication conditions. Lubrication mechanism is modelled using ANSYS CFD, and volume fraction of oil availability during mating of gears teeth has evaluated under various speeds. Teeth of wire-cut EDM gears are stronger compared to hobbed gears for the same dimensions. Teeth surface roughness of the WEDM gears is much higher compared to hobbed gears. Wear of the WEDM gears is lower compared to hobbed gears.