Electroerosion Process in Gears 1

[WendelTrento]

Dears,

If possible, could you answer the question below.

I'm making a Gear with Straight Teeth.
2.5 module
43 Teeth.
Material 8620

Carburizing Process
Surface Hardness: 55 HRC Min.
Core Hardness: 22 to 34 HRC
Effective layer: 0.4 - 0.8 millimeters

Manufacturing process:

1 - I pre-rough the gear (through the electro-erosion process), leaving a 0.2 millimeter over metal on the face.
2 - I carry out the cementation, adding the 0.2 millimeters in the layer.
3 - I carry out the final fabrication (by the electro erosion process), remonstrating the 0.2 millimeters.

The reason for the surplus metal is:
Remove dimensional distortions in gear.
Remove the percentage of autenite retained near the surface.
Remove intergranular oxidation.

The question is, can I use the EDM process for the final manufacture (Final dimension) of the gear? Does the electroerosion process generate a "Thermally Affected Zone" and is this HAZ harmful to the gear surface?

Att,
Wendel Trento

 

[EdStainless]

An EDM surface will have re-cast metal on it from the melting during the arc process.
I would doubt that it is smooth enough to serve in gears.
And it might have metallurgical issues as well.
Better to final grind or hone the surfaces of the teeth.

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P.E. Metallurgy, consulting work welcomed

 

[mfgenggear]

WendelTrendo

the whole process as stated has issues,
straight teeth
elector erosion is the same as wire EDM unless I am missing something
the manufacturing method is dictated by the required DIN or AGMA quality.
to many unknowns to specify if this is viable.
straight cut gears could be or do you mean spur gears with a straight lead, (not helical)
or non involute gears) if not involute are they cylindrical or are they rack type.