ABSTRACT This work aims to report the quality of the high contact ratio asymmetrical gear tooth manufactured through wire cut electrical discharge machining(WCEDM) process and static load capacity of the gear tooth. The effect of various process parameters such as peak current (IP), pulse on time (Ton), pulse off time (Toff) and servo voltage (SV) on the performance parameters such as Surface roughness (Ra) and Kerf width (Kf) has been examined on the regular shaped specimen. Taguchi method was used with process parameters at three levels and the significance of WCEDM process parameters was studied through analysis of variance (ANOVA). Based on the significant process parameter values, the gears were manufactured and gear tooth errors such as profile, lead and pitch errors were estimated based on DIN3962 Standard using the Gleason inspection system and found that the range of quality of the gear obtained through this process was from Q8-Q11. The experimental test results conducted to explore the tooth root load carrying capacity of the gear tooth revealed that the gear with lower pressure angle at the non-drive side (17º-20º) has a maximum load carrying capacity and maximum yielding when compared to symmetric (20º-20º) and asymmetric gears with higher pressure angle at the non-drive side (22º-20º).

中文翻译：

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WCEDM工艺加工高接触比非对称轮齿的质量及齿根承载能力研究

摘要 这项工作旨在报告通过线切割电火花加工 (WCEDM) 工艺制造的高接触比非对称轮齿的质量和轮齿的静载荷能力。峰值电流（IP）、脉冲开启时间（Ton）、脉冲关闭时间（Toff）和伺服电压（SV）等各种工艺参数对表面粗糙度（Ra）和切缝宽度（Kf）等性能参数的影响已在规则形状的试样上进行了检查。田口方法用于三个水平的工艺参数，并通过方差分析（ANOVA）研究 WCEDM 工艺参数的显着性。根据重要的工艺参数值，制造齿轮和齿轮齿误差，如轮廓、使用格里森检验系统根据DIN3962标准估计导程和螺距误差，发现通过该过程获得的齿轮质量范围为Q8-Q11。研究齿轮齿根承载能力的实验测试结果表明，与对称齿轮相比，非驱动侧（17º-20º）压力角较小的齿轮具有最大承载能力和最大屈服（ 20º-20º) 和非驱动侧压力角更高的非对称齿轮 (22º-20º)。