Two-step method of nanosecond pulse laser ablation manufacturing of miniature bevel line gears

Abstract

Miniature gears have important research value and application prospects in micro-scale machinery. The existing manufacturing methods for miniature gears produce spur gears on the micron scale and spur, helical and bevel gears on the millimetre scale. However, there is no mature process for gears on the micron scale for angular transmissions, such as bevel gears. This article reports for the first time the micro-machining of a miniature bevel gear with an external size of 1–2 mm based on a novel gear structure: the bevel line gear. First, a novel manufacturing method, namely the two-step method of nanosecond pulse laser ablation (NSPLA), is proposed. Then, a sample of a miniature bevel line gear is fabricated from 6061 aluminium alloy with a top angle of 90°, external diameter of 1375 μm, tooth number of 3 and average tooth width of 20 μm. Finally, the accuracy of the sample is studied to confirm the practicability of the proposed method.