Experimental investigations on redefining the surface quality of bevel gears by pulsed electrochemical honing

This paper reports on the influence of electrolyte flow rate and rotary speed of workpiece on the quality of straight bevel gears finished by a pulsed electrochemical honing process. Electrolyte flow rate was varied at four levels and rotary speed at three levels. The quality of bevel gear was studied in terms of the percentage variations in three surface roughness parameters (i.e. centre line roughness, maximum height of roughness and average maximum height of roughness), microgeometry parameters (i.e. variation in pitch and runout) and surface topography (i.e. vertical deviation from the ideal flank surface of gear tooth). Pre-identified values of electrolyte composition, pulse-on time, pulse-off time and finishing time were used. Microstructure and microhardness of the best finished gear were also studied. The optimised values of electrolyte flow rate (20 Lpm) and rotary speed of workpiece gear (40 rpm) yielded significant percentage enhancements in surface roughness parameters i.e. 62.45% in R-a, 60.58% in R-t and 53.98% in R-z, in addition improvement in microgeometry and surface topography enhanced bevel gear quality from DIN 8 to DIN 6 standard for the best finished gear.