ABSTRACT

Miniature gears are used in the biomedical, automotive, and aerospace industries for advanced automatic transmission. Significantly few finishing processes can be utilized to finish miniature gears due to the narrow spacing between the miniature gear teeth profiles. In the present study, a novel uniform flow restrictor, an exact negative replica of the miniature gear teeth profiles, is designed and developed while using the rotational magnetorheological fluid-based finishing process. The effect of critical parameters on the process’s performance has been studied through response surface methodology (RSM). The surface roughness and surface texture of the finished gear profiles with different magnetorheological fluids with and without using flow restrictors are compared for consistent and precise finishing. After finishing, it is observed that all manufacturing defects in SS316L miniature spur gear are entirely removed. Also, the ultrafine surface roughness of 23.9 nm (Ra) is achieved using a uniform flow restrictor at miniature gear teeth profiles. The forces responsible for finishing gear profiles are also simulated using Comsol® Multiphysics for understanding the controlling mechanism correctly. A mathematical model for material removal using abrasive grains on gear profiles is carried out to anticipate material dislodgement mechanism during finishing.

摘要

微型齿轮用于生物医学、汽车和航空航天工业，用于先进的自动变速器。由于微型齿轮齿廓之间的间距很窄，可以使用非常少的精加工工艺来精加工微型齿轮。在本研究中，使用基于旋转磁流变流体的精加工工艺，设计和开发了一种新颖的均匀限流器，即微型齿轮齿廓的精确负复制品。通过响应面法 (RSM) 研究了关键参数对工艺性能的影响。比较使用和不使用限流器的不同磁流变流体的成品齿轮轮廓的表面粗糙度和表面纹理，以获得一致和精确的精加工。完成后，据观察，SS316L 微型直齿轮的所有制造缺陷都被完全消除。此外，23.9 nm (Ra) 的超精细表面粗糙度是通过在微型齿轮齿廓上使用均匀限流器实现的。为了正确理解控制机制，还使用 ​​Comsol® Multiphysics 模拟了负责完成齿轮轮廓的力。使用齿轮轮廓上的磨粒去除材料的数学模型用于预测精加工过程中的材料脱落机制。为了正确理解控制机制，还使用 ​​Comsol® Multiphysics 模拟了负责完成齿轮轮廓的力。使用齿轮轮廓上的磨粒去除材料的数学模型用于预测精加工过程中的材料脱落机制。为了正确理解控制机制，还使用 ​​Comsol® Multiphysics 模拟了负责完成齿轮轮廓的力。使用齿轮轮廓上的磨粒去除材料的数学模型用于预测精加工过程中的材料脱落机制。