Modeling and Experimental Validation of Volumetric Material Removal Rate and Surface Roughness Depth of Straight Bevel Gears in Pulsed-ECH Process

Modeling and Experimental Validation of Volumetric Material Removal Rate and Surface Roughness Depth of Straight Bevel Gears in Pulsed-ECH Process

This paper describes development of theoretical models of volumetric material removal rate (MRR) and surface roughness depth (Rz) of straight bevel gears finished by pulse electrochemical honing (PECH) process in terms of the most influencing parameters namely applied voltage, pulse-on time, pulse-o...

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Main Authors: Pathak, Sunil, Jain, N. K.
Format: Article
Language:English
Published: Elsevier Ltd 2017
Subjects:
T Technology (General)
Online Access:http://umpir.ump.edu.my/id/eprint/14237/
http://umpir.ump.edu.my/id/eprint/14237/
http://umpir.ump.edu.my/id/eprint/14237/
http://umpir.ump.edu.my/id/eprint/14237/2/Modeling%20and%20experimental%20validation%20of%20volumetric%20material%20removal%20rate%20and%20surface%20roughness%20depth%20of%20straight%20bevel%20gears%20in%20pulsed-ECH%20process%201.pdf
id ump-14237
recordtype eprints
spelling ump-142372018-06-28T01:42:31Z http://umpir.ump.edu.my/id/eprint/14237/ Modeling and Experimental Validation of Volumetric Material Removal Rate and Surface Roughness Depth of Straight Bevel Gears in Pulsed-ECH Process Pathak, Sunil Jain, N. K. T Technology (General) This paper describes development of theoretical models of volumetric material removal rate (MRR) and surface roughness depth (Rz) of straight bevel gears finished by pulse electrochemical honing (PECH) process in terms of the most influencing parameters namely applied voltage, pulse-on time, pulse-off time, finishing time, inter-electrode gap, electrolyte conductivity and workpiece gear rotary speed. Equations for computing flank surface area of gear tooth flank surfaces in terms geometric parameters of involute profile of straight bevel gears were also developed. The developed models were validated by conducting twelve experiments using one-factor-at-a-time approach and varying applied voltage, pulse-on time and pulse-off time each at four levels. Values and trends of variation of volumetric MRR and surface roughness depth predicted by the proposed models have shown very close agreement with corresponding experimental values and their trends. Minimum prediction errors for the proposed models were found to be −3.3% and 1% for volumetric MRR and surface roughness depth respectively. Models and validation results have also revealed the existence of optimum ranges of voltage, pulse-on time and pulse-off time to optimize volumetric MRR and depth of surface roughness. Analysis of different aspects of surface quality (i.e. surface finish, material ratio curve, micro-geometry, tooth flank topology) and surface integrity (i.e. microstructure and micro-hardness) of the best-finished gear have shown considerable improvements in them. Elsevier Ltd 2017 Article PeerReviewed application/pdf en http://umpir.ump.edu.my/id/eprint/14237/2/Modeling%20and%20experimental%20validation%20of%20volumetric%20material%20removal%20rate%20and%20surface%20roughness%20depth%20of%20straight%20bevel%20gears%20in%20pulsed-ECH%20process%201.pdf Pathak, Sunil and Jain, N. K. (2017) Modeling and Experimental Validation of Volumetric Material Removal Rate and Surface Roughness Depth of Straight Bevel Gears in Pulsed-ECH Process. International Journal of Mechanical Sciences, 124-5. pp. 132-144. ISSN 0020-7403 http://doi.org/10.1016/j.ijmecsci.2017.03.011 doi: 10.1016/j.ijmecsci.2017.03.011
repository_type Digital Repository
institution_category Local University
institution Universiti Malaysia Pahang
building UMP Institutional Repository
collection Online Access
language English
topic T Technology (General)
spellingShingle T Technology (General)
Pathak, Sunil
Jain, N. K.
Modeling and Experimental Validation of Volumetric Material Removal Rate and Surface Roughness Depth of Straight Bevel Gears in Pulsed-ECH Process
description This paper describes development of theoretical models of volumetric material removal rate (MRR) and surface roughness depth (Rz) of straight bevel gears finished by pulse electrochemical honing (PECH) process in terms of the most influencing parameters namely applied voltage, pulse-on time, pulse-off time, finishing time, inter-electrode gap, electrolyte conductivity and workpiece gear rotary speed. Equations for computing flank surface area of gear tooth flank surfaces in terms geometric parameters of involute profile of straight bevel gears were also developed. The developed models were validated by conducting twelve experiments using one-factor-at-a-time approach and varying applied voltage, pulse-on time and pulse-off time each at four levels. Values and trends of variation of volumetric MRR and surface roughness depth predicted by the proposed models have shown very close agreement with corresponding experimental values and their trends. Minimum prediction errors for the proposed models were found to be −3.3% and 1% for volumetric MRR and surface roughness depth respectively. Models and validation results have also revealed the existence of optimum ranges of voltage, pulse-on time and pulse-off time to optimize volumetric MRR and depth of surface roughness. Analysis of different aspects of surface quality (i.e. surface finish, material ratio curve, micro-geometry, tooth flank topology) and surface integrity (i.e. microstructure and micro-hardness) of the best-finished gear have shown considerable improvements in them.
format Article
author Pathak, Sunil
Jain, N. K.
author_facet Pathak, Sunil
Jain, N. K.
author_sort Pathak, Sunil
title Modeling and Experimental Validation of Volumetric Material Removal Rate and Surface Roughness Depth of Straight Bevel Gears in Pulsed-ECH Process
title_short Modeling and Experimental Validation of Volumetric Material Removal Rate and Surface Roughness Depth of Straight Bevel Gears in Pulsed-ECH Process
title_full Modeling and Experimental Validation of Volumetric Material Removal Rate and Surface Roughness Depth of Straight Bevel Gears in Pulsed-ECH Process
title_fullStr Modeling and Experimental Validation of Volumetric Material Removal Rate and Surface Roughness Depth of Straight Bevel Gears in Pulsed-ECH Process
title_full_unstemmed Modeling and Experimental Validation of Volumetric Material Removal Rate and Surface Roughness Depth of Straight Bevel Gears in Pulsed-ECH Process
title_sort modeling and experimental validation of volumetric material removal rate and surface roughness depth of straight bevel gears in pulsed-ech process
publisher Elsevier Ltd
publishDate 2017
url http://umpir.ump.edu.my/id/eprint/14237/
http://umpir.ump.edu.my/id/eprint/14237/
http://umpir.ump.edu.my/id/eprint/14237/
http://umpir.ump.edu.my/id/eprint/14237/2/Modeling%20and%20experimental%20validation%20of%20volumetric%20material%20removal%20rate%20and%20surface%20roughness%20depth%20of%20straight%20bevel%20gears%20in%20pulsed-ECH%20process%201.pdf
first_indexed 2023-09-18T22:17:45Z
last_indexed 2023-09-18T22:17:45Z
_version_ 1777415451609923584

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