Experimental investigation of precision finishing of spur gears by pulse electrochemical honing (PECH) process

Abstract

This paper is an aim to present the precision finishing of spur gears by pulse electrochemical honing (PECH) process to study the effects of finishing time, electrolyte-related parameters (electrolyte temperature, electrolyte composition), pulse-on time (T on) and pulse-off time (T off) on measure of process performances, i.e., percentage improvement in average surface roughness value (PIR a) and maximum surface roughness value (PIR tm). A special type of cathode gear has been designed having the capability of varying the rate of electrolytic dissolution steplessly along the full profile of the work piece gear. Optimum values of process parameters such as finishing time, electrolyte composition, electrolyte temperature, pulse-on time and pulse-off time have been estimated using graphical analysis. Work samples were also analysed before and after the PECH using the optical profiler to visualise the effects of process parameters on gear tooth profile. Key features of developed PECH setup are also highlighted. Copyright © 2012 Inderscience Enterprises Ltd.