Prediction of tribological performance of electrochemical honed bevel gears teeth profile

Gears with involute teeth profile lack appropriate finishing technique for final finishing. Electrochemical honing (ECH) is evolved as a promising gear finishing technique for its micro–removal characteristic. This paper discusses the precision finishing of bevel gears by electrochemical honing process; its prospective features and capabilities. The characteristic features of the process were critically evaluated by optimisation controlled ECH process involving three key input parameters (i.e., current, rotating speed and electrolyte concentration) and employing improvement in bearing ratio as process performance parameter to predict tribological performance of gear teeth profile. The present study shows that the input parameters have significant influences on process performance and the values predicted by developed mathematical model are in close proximity of the actual experimental results.