Effect of Processing Time in High-Precision Finishing of Helical Gear by Pulse-Electrochemical Honing (PECH) Process

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.