Electrochemical Honing-An Advanced Process for Gear Finishing

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.