Abstract: This research focuses on identifying the optimal Wire-EDM parameters to enhance the quality and precision of machining external spur gears with straight teeth using C45 steel. The study investigates three key parameters—wire feed rate (n, mm/s), short-circuit ratio (s), and wire compensation (f, mm)—employing the Box-Behnken experimental design. Analysis of variance indicated that wire feed rate (n) and short-circuit ratio (s) are associated with variations in surface roughness (Ra), while wire compensation (f) is associated with changes in the addendum circle diameter (D). By utilizing the Response Optimizer module in Minitab, the study determined the minimum surface roughness Ra_min and the maximum addendum circle diameter D_max, establishing a reliable optimal parameter set. This parameter set, validated through GOM Inspect software, meets design tolerances and can be applied to Wire-EDM machining of various components.

Keywords: Wire-EDM, Spur Gear, C45 Steel, Box-Behnken Method, Surface Roughness, Addendum Circle Diameter

Pages: 195-207