Modern manufacturing of miniature gears

This paper explains and demonstrates how miniature gears of excellent surface quality can be manufactured by modern machining methods. Necessity of gear finishing by post processes such as grinding, lapping, honing etc. is the major limitation of all conventional methods of miniature gear manufacturing. To overcome this limitation, modern machining methods such as wire-EDM, abrasive waterjet machining, and laser beam machining etc. have been explored. It resulted in significant achievements in geometric accuracy, surface finish, and integrity of miniature gears. Using modern machining methods, it is possible to manufacture gears equipped with precision finish (average roughness 1 µm), high geometric accuracy (DIN quality 5), and defect-free tooth surfaces at significantly low cost. This paper aims to facilitate researchers by providing information on important aspects as regards to the manufacturing of miniature gears by modern machining methods and hopes research and development in this area to establish the field further.