Parametric optimisation of ECH of spur gears by Taguchi technique

This paper presents the precision finishing of spur gears by ECH process to investigate the effects of finishing time, current, and electrolyte-related parameters on percentage improvement in maximum surface roughness value (PIRtm). The main experimentation was designed using Taguchi's experimental design technique. SEM photographs were taken and optical profilometry was conducted before and after the experimentation to identify the improvement of surface quality of gear teeth profiles. For the present study, a special type of cathode gear which has been developed by sandwiching a copper gear between two bakelite gears, having the capability of varying the rate of electrolytic dissolution steplessly along the full profile of the workpiece gear made of EN8. The results were analysed by ANOVA to observe the effects of input parameters on the performance. At the optimum setting of parameters, the present study shows an improvement of 62% in maximum surface roughness value.