Manufacturing Technology Today

J. P. Misra ¹, P. K. Jain ¹, D. K. Dwivedi ¹, N. K. Mehta ¹

Affiliations
1 Dept of Mechanical and Industrial Engg., Indian Institute of Technology, Roorkee, IN

Abstract

From last few decades, the gear finishing processes draw the attention of researchers to improve the service performance of gears which is a very essential element in many crucial products for mankind namely automotive products, ships, wind-power systems, machine tools or general gear boxes. This paper presents the experimental investigation of bevel gear finishing using an abrasive bonded mitre gear in an indigenously designed and developed experimental setup. The experimentation has been carried out to evaluate the effect of finishing time and rotating speed of workpiece on improvement in surface quality of gear teeth profile and material removal rate (MRR) of the process. Surface quality of the finished gear has been also analysed and it was found that the process produces a smooth surface by reducing irregularities. Furthermore, future scopes of the process are also highlighted.

Keywords

Bevel Gear, Gear Finishing, Abrasives, Surface Integrity.

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J. P. Misra ¹, P. K. Jain ¹

Affiliations
1 Mechanical and Industrial Engg. Dept., Indian Institute of Technology, Roorkee, IN

Abstract

This paper presents the study of electrochemical honing process used for gear finishing. Electrochemical Honing (ECH) is used for finishing internal cylinders and gears, based on the combination of Electrochemical Machining (ECM) process having high material removal capability and controlled functional surface generating capability of conventional honing process in a single operation. The workpiece hardness is not a limiting factor for ECH process and as the material removal mostly occurs due to electrolytic dissolution; a nano level finish is achieved and hence, it can be used widely in automobile, avionics, petrochemical, power generation, and fluid power industries. This paper describes the process principle, parameters, capabilities, equipment details of ECH of gears and a comparative study of different gear finishing processes with some directions for future research with an objective to revive the interest of the global research community to further mature this process.

Keywords

ECM, Honing, ECH, Gear Finishing.

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P. Jerripothu ¹, P. K. Jain ¹, N. K. Mehta ¹, J. P. Misra ¹

Affiliations
1 Mechanical & Indl Engg Dept, Indian Institute of Technology Roorkee, Roorkee, Uttarakhand, IN

Abstract

Gears are used to transmit power and/or motion from one shaft to another by means of gradual engagement of teeth. The running performance of gears greatly relies on the surface quality of gear teeth profile. This paper reports the effect of processing time during Pulse-Electrochemical Honing (PECH) which is a hybrid micro-finishing process combining the faster material removal capability of electrochemical machining and surface generating capability of honing with assistance of pulse power supply and reported as one of the most potential process for gear finishing. In the present study, the effect of processing time on surface profile parameters of gear teeth profile (i.e. R_a, R_z, and R_tm) has been investigated and analysed. Surface microtopography characteristics have also been studied using optical profilometer to evaluate the contribution of the process in improving the surface quality of gear teeth profile. The emphatic features of developed experimental setup have also been highlighted.

Keywords

Gears, Hybrid Machining, PECH, Surface Microtopography Characteristics.

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