A Study of Influence of Electrolyte Composition on ECH of Bevel Gears using Mixture D-Optimal Design
This paper discusses the experimental investigation to find out the optimal electrolyte composition in improving the surface quality of the gear teeth profile during surfacing finishing of bevel gears by the electrochemical honing process. In this study, AISI 1040 was used as the workpiece material, mixtures of sodium chloride and sodium nitrate in different ratios were used as the input parameter, and the percentage improvement in the surface roughness and material removal rate of the process were used as measures of process performance. The experimental runs were designed according to the Mixture DOptimal design. The analysis of the experimental outcome was carried out and 80% NaCl + 20% NaNO3 was found to be theoptimal electrolyte composition to conduct the confirmation experiments. The finding of the study establishes the process for precision finishing of bevel gears.
Electro-Chemical Honing of Gears — A new Method of Gear Finishing
The authors foresee that a productive high accuracy long tool life gear finishing method can be developed on ECH principle. Experiments show an accuracy in profile of 0.01mm. Crowning in tooth width can easily be obtained by photo-electric control of D.C. supply, while surface finish is a little bit better than honing. Machining time for a hardened gear of m=3.25, z=32, B=40 mm is about 6 minutes, stock removal 0.06mm over chord. Research works are made in three respects: (1) The ability of correcting geometric error in ECH of gears, its principle and methods of improving. (2) Dynamic behavior of dual-flank meshing process in ECH of gears. (3) False tooth profile derived from dual-flank meshing process, its theorectical analysis and methods of preventing.
Characteristics of trochoids and their application to determining gear teeth fillet shapes
Some interesting characteristics of trochoids are discussed in this paper and a new concept of virtual involute is introduced. These characteristics prove very useful in determining the exact tooth fillet shape generated by racks consisting of circular arcs and straight line segments. The fillet curves generated by racks with a protuberance or with a chamfered tip are discussed in detail. A numerical example is given to illustrate their application.