Manufacturing and Structural Evaluation of Precision Gears Using Non Conventional Machining Process

The growing need for high precision components has increased the rate of adoption of non-conventional machining processes in the current manufacturing. This paper gives a manufacturing and structural analysis of the spur gears produced by means of Wire Electrical Discharge Machining (EDM) with regards to three materials such as Aluminum (LY-10), Brass (Brass-260) and Mild Steel (AISI-1020). The gear geometries were CAD modelled and machined on EDM Machine at constant discharge parameters. Comparative machinability was evaluated by measuring time of cutting and the structural performance was assessed by measuring total deformation and equivalent stress using the finite element analysis (FEA) in ANSYS workbench. The findings showed that aluminum had the shortest time cut with the highest deformation. Brass showed low deformation when subjected to moderate stress but takes the shortest time to machine and has the highest strength and dimensional stability as compared to the mild steel. These results establish Wire EDM as an accurate and flexible process of producing gears with high precision, and generate a relationship between material characteristics, machining behavior and structural reaction towards the sophisticated optimization of design in production processes.

• Publication year

  2025

• Venue

  2025 5th International Conference on Digital Futures and Transformative Technologies (ICoDT2)

• Publication date

  2025-12-17

• Fields of study

  Not labeled

• Identifiers
  DOI 10.1109/ICoDT269104.2025.11360717
• External record

  Open on Semantic Scholar

• Source metadata

  Semantic Scholar

• No claims are published for this paper.

• No concepts are published for this paper.

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