Surface morphology investigation of miniature gears manufactured by abrasive water jet machining

In this paper, surface morphology investigation of miniature spur gears manufactured by abrasive water jet machining is discussed. Water jet pressure, abrasive flow rate and stand-off-distance are the varying input parameters to study the surface morphology (surface roughness and topography) of the machined gears. From the investigation, the water jet pressure has highly influenced (with 47% contribution) the surface quality and found as a predominant process parameter. SEM micrograph study found that wear scars and clinging effects are the major surface defects found over the machined surfaces of the gear teeth. Maximum and minimum peaks of the wear tracks are observed with white light spectroscope. The best surface morphology with average surface roughness value 1.08 μm was achieved at 350 MPa water jet pressure, 225 g/min abrasive mass flow rate, and 1mm stand-off distance. The present work identifies the potential of AWJM process for manufacturing of high quality miniature gears.