Small modulus metal gears are widely utilized in precision machinery, where their performance is heavily influenced by surface quality. Conventional contact measurement methods often fall short in providing accurate surface roughness measurement due to the intricate geometries and small scale of these gears. This study employs laser confocal microscopy, a non-contact measurement method, to observe the 3D micro-morphology and assess the surface roughness of gears fabricated by metal injection molding (MIM) and selective laser melting (SLM). The findings reveal that the MIM-manufactured gears exhibit superior surface roughness compared to SLM samples, attributable to the finer particle size of MIM powders. Unlike traditional machining, these manufacturing methods involve sintering processes that contribute to surface unevenness and porosity, resulting in elevated Sz and Sdr roughness values, which do not fully represent the actual surface quality. Interestingly, the tooth flank area consistently displays lower roughness than the tooth top area, warranting further investigation into this disparity. This study demonstrates that laser confocal microscopy provides comprehensive surface quality inspection for small and intricate parts, with promising implications for high-precision quality assessment.

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Inspection and Analysis of Surface Quality of Small Modulus Gears Manufactured by Metal Injection Molding and SLM

  • Xunwei Wang,
  • Baozhen Lei,
  • Harald Löwe,
  • Shengna Zhao

摘要

Small modulus metal gears are widely utilized in precision machinery, where their performance is heavily influenced by surface quality. Conventional contact measurement methods often fall short in providing accurate surface roughness measurement due to the intricate geometries and small scale of these gears. This study employs laser confocal microscopy, a non-contact measurement method, to observe the 3D micro-morphology and assess the surface roughness of gears fabricated by metal injection molding (MIM) and selective laser melting (SLM). The findings reveal that the MIM-manufactured gears exhibit superior surface roughness compared to SLM samples, attributable to the finer particle size of MIM powders. Unlike traditional machining, these manufacturing methods involve sintering processes that contribute to surface unevenness and porosity, resulting in elevated Sz and Sdr roughness values, which do not fully represent the actual surface quality. Interestingly, the tooth flank area consistently displays lower roughness than the tooth top area, warranting further investigation into this disparity. This study demonstrates that laser confocal microscopy provides comprehensive surface quality inspection for small and intricate parts, with promising implications for high-precision quality assessment.